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

Materials

Removal

NOTICE: Do not loosen any fittings or plugs on the high-pressure fuel pump.

1. Release the fuel system pressure.
   Refer to: Fuel System Pressure Release (310-00A Fuel System - General Information - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
   

1. Disconnect the battery.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
   

1. 
   
   1. Disconnect the high-pressure fuel pump fuel feed tube spring lock coupling.
      Refer to: Spring Lock Couplings (310-00A Fuel System - General Information - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
      
   2. Disconnect the high-pressure fuel pump electrical connector.
      

1. NOTICE: To release the fuel pressure in the high pressure fuel tube, wrap the high-pressure fuel pump flare nut with a shop towel to absorb any residual fuel pressure during the loosening of high-pressure fuel pump flare nut.

   Disconnect the high-pressure fuel tube flare nuts. Remove and discard the high-pressure fuel tube.
   

1. NOTE: Alternately loosen the high-pressure fuel pump bolts one complete revolution at a time.

   Remove the high-pressure fuel pump bolts and then remove the high-pressure fuel pump.
   

1. Remove the high-pressure fuel pump drive tappet.
   

1. Inspect the high-pressure fuel pump tappet. If any flat spots or scoring are found, especially in the indicated areas, then inspect the high-pressure fuel pump and the high-pressure fuel pump tappet drive lobe. Install new components as necessary.
   

Installation

1. The cam lobe for the high-pressure fuel pump must be at BDC for the high-pressure fuel pump installation.
   

1. NOTICE: Only rotate the crankshaft Clockwise (CW) or damage to the engine may occur.

   Using the crankshaft pulley bolt, turn the crankshaft until the high-pressure fuel pump cam lobe is at BDC.
   

1. Apply clean engine oil to the high-pressure fuel pump drive unit bore and the drive lobe and the roller tappet. Install the high-pressure fuel pump tappet.
   Material: Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

1. Install a new high-pressure fuel pump O-ring seal. Lubricate with clean engine oil.
   Material: Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

1. NOTE: Make sure that 2 new high-pressure fuel pump mounting bolts are installed.

   Install the high-pressure fuel pump and loosely install the high-pressure fuel pump bolts, alternately tighten each bolt 90° at a time in turn until the torque is achieved.
   Torque: 80 lb.in (9 Nm)

1. NOTE: Only tighten the 2 high pressure fuel tube flare nuts finger tight at this stage.

   NOTE: Make sure that a new high pressure fuel tube is installed.

   NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas.

   Tighten the high-pressure fuel tube flare nuts in the following 3 stages.
   Torque:
     Stage 1:  15 lb.ft (21 Nm)
     Stage 2:  Wait 5min
     Stage 3:  15 lb.ft (21 Nm)

1. 
   
   1. Connect the high-pressure fuel pump fuel feed tube spring lock coupling.
      Refer to: Spring Lock Couplings (310-00A Fuel System - General Information - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
      
   2. Connect the high-pressure fuel pump electrical connector.
      

1. Connect the battery.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
   

1. Pressurize the fuel system.
   Refer to: Fuel System Pressure Release (310-00A Fuel System - General Information - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).