Ford Fusion: Fuel Charging and Controls - 1.5L EcoBoost (118kW/160PS) – I4 / High-Pressure Fuel Pump Drive Unit. Removal and Installation

Materials

Removal

1. Remove the high-pressure fuel pump.
   Refer to: High-Pressure Fuel Pump (303-04A Fuel Charging and Controls - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
   

1. Remove the valve cover.
   Refer to: Valve Cover (303-01A Engine - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
   

1. NOTICE: The CMP sensor must be removed to prevent damage from the heat gun.

   • Disconnect the CMP sensor electrical connector.
     
   • Remove the CMP sensor retaining bolt.
     
   • Remove the CMP sensor.
     
   • Disconnect the vacuum harness retainer.
     

1. NOTICE: Use a heat gun to soften the flange sealant, this will aid in the removal of the fuel pump mounting bracket. Failure to follow these directions may result in damage to the fuel pump mounting bracket.

Installation

1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.

   Clean the high-pressure fuel pump drive unit sealing surface.
   Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.

   Clean the engine cylinder head sealing surface.
   Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

1. NOTE: Sealer should be squeezed out of the joint where it interfaces with the valve cover. The components must be installed within 5 minutes of applying the sealant.

   Apply a bead of flange sealant as shown.
   Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

1. Install a new O-ring seal.
   

1. Install the high-pressure fuel pump drive unit, then install and tighten the high-pressure fuel pump drive unit retaining bolts in sequence shown, in the following 3 stages.
   Torque:
     Stage 1:  Tighten bolts 1-8 in sequence to: :   35 lb.in (4 Nm)
     Stage 2:  Tighten bolts 1-8 in sequence to: :   124 lb.in (14 Nm)
     Stage 3:  Tighten bolts 9 and 10 to: :   97 lb.in (11 Nm)

1. • Connect the vacuum harness retainer.
     
   • Install the CMP sensor.
     
   • Install and tighten the CMP sensor retaining bolt.
     Torque: 80 lb.in (9 Nm)
   • Connect the CMP sensor electrical connector.
     

1. Install the valve cover.
   Refer to: Valve Cover (303-01A Engine - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
   

1. Install the high-pressure fuel pump.
   Refer to: High-Pressure Fuel Pump (303-04A Fuel Charging and Controls - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).