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CTM502 - PowerTech™ E 4.5 and 6.8L Diesel EnginesLevel 16 Electronic

Fuel System With Denso HPCR
Remove and Install High Pressure Fuel Pump

Remove and Install High Pressure Fuel Pump

Remove High Pressure Fuel Pump

CD30862-UN: Remove high pressure fuel pump

CD30886-UN: Pump position sensor (high pressure pump removed)

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CD30863-UN: Remove high pressure fuel pump

LEGEND:

A - Suction Control Valve

B - Fuel Temperature Sensor
C - Pump position sensor
D - High pressure fuel outlet
E - Leak-off line connection
F - Fuel supply inlet
G - Adapter plate nut

1. Disconnect wiring harness from suction control valve (A), from fuel temperature sensor (B) and from pump position
sensor (C).

2. Remove high pressure fuel lines (D).

3. Remove fuel leak-off line (E).

4. Disconnect fuel supply line (F).

5. Remove the 3 nuts (G) fixing adapter plate on engine front plate.

6. Carefully remove high pressure pump assembly from engine.

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CD30864-UN: High pressure fuel pump exploded view

LEGEND:

A - High pressure fuel pump

B - Adapter plate
C - Drive gear
D - Nut
E - O-ring
F - Pump position sensor
G - Fuel supply fitting
H - Fuel leak-off fitting
I - Cap screw (high pressure pump-to-adapter plate)

Disassemble and Reassemble High Pressure Fuel Pump

A) Disassembling

1. Remove gear (C) using JDG1560 tool. Use a vise with claws to block the gear when removing gear.

2. Remove the two cap screws (I) and separate high pressure pump (A) from adapter plate (B).

3. Replace parts as necessary.

B) Reassembling

1. Install high pressure pump (A) on adapter plate (B) with a new O-ring (E). Tighten the 2 cap screws (I) to specification.

Item Measurement Specification

High pressure pump to adapter Torque 40 N·m (30 lb.-ft.)

plate

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2. Install gear (C) on pump shaft then tighten nut (D) to specification. Use a vise with claws to block the gear when
tightening.

Item Measurement Specification

High pressure pump gear nut Torque 95 N·m (70 lb.-ft.)

3. Install pump position sensor (F) onto adapter plate then tighten to specification.

Item Measurement Specification

Pump position sensor to adapter Torque 15 N·m (11 lb.-ft.)

plate

4. Install fuel supply elbow fitting (G) on high pressure pump. Orient fitting to be in line with fuel line. Tighten fitting nut to
specification.

Item Measurement Specification

Fuel supply elbow fitting nut-to-high Torque 20 N·m (15 lb.-ft.)

pressure pump

5. Install fuel leak-off fitting (H) on high pressure pump. Orient fitting vertical pointing down. Tighten fitting nut to
specification.

Item Measurement Specification

Fuel leak-off fitting nut-to-high Torque 15 N·m (11 lb.-ft.)

pressure pump

CD30868-UN: Install O-rings on adapter plate

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CD30865-UN: Plug to access gear timing mark

CD30866-UN: Gear timing mark

CD30867-UN: Install high pressure pump

LEGEND:

A - Plug to access gear timing mark

B - O-ring (adapter plate-to-front plate
C - O-ring (camshaft sensor)
D - High pressure pump gear timing mark
E - High pressure fuel line
F - Leak-off line
G - Fuel supply line

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H - Adapter plate nut

I - Suction control valve
J - Fuel temperature sensor
K - Camshaft sensor

Install high pressure fuel pump

1. Rotate engine to Top Dead Center (TDC) of number 1 cylinder and install JDG1571 Timing Pin in flywheel.

2. Remove plug (A) to access gear timing mark.

3. Replace O-rings (B & C) on adapter plate then install high pressure pump so that timing mark (D) can be seen through
the timing gear cover opening as shown.

4. Install the 3 nuts (H) and tighten to specification.

Item Measurement Specification

Adapter plate to engine front plate Torque 40 N·m (30 lb.-ft.)

5. Install high pressure fuel lines (E) finger tight.

6. Initial torque. Tighten high pressure fuel line (E) to specification at both ends.

Item Measurement Specification

High pressure fuel line Torque 5 N·m (4 lb.-ft.)

7. Final torque. Tighten high pressure fuel line (E) to specification at both ends.

Item Measurement Specification

High pressure fuel line Torque 22 N·m (16 lb.-ft.)

Torque Turn 60 degree

8. Install leak-off line (F) then tighten tube nuts until seated on fitting shoulder.

9. Install fuel supply line (G) then tighten tube nut until seated on fitting shoulder.

10. Reconnect wiring harness to suction control valve (I), to fuel temperature sensor (J) and to camshaft sensor (K).

11. Reinstall plug (A). Tighten to specification.

Item Measurement Specification

Plug to access gear timing mark Torque 50 N·m (37 lb.-ft.)

12. Bleed fuel system.

AS58880,000115E-19-20130617

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