Lincoln Corsair: Fuel Charging and Controls - 2.0L EcoBoost (177kW/240PS) – MI4 / Removal and Installation - High-Pressure Fuel Pump

Removal

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

1. With the vehicle in NEUTRAL, position it on a hoist.
   Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
   

1. Release the fuel system pressure.
   Refer to: Fuel System Pressure Release (310-00A Fuel System - General Information - 2.0L EcoBoost (177kW/240PS) – MI4, General Procedures).
   

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

1. Remove the air cleaner outlet pipe.
   Refer to: Air Cleaner Outlet Pipe (303-12A Intake Air Distribution and Filtering - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
   

1. Remove the exhaust gas recirculation valve.
   Refer to: Exhaust Gas Recirculation (EGR) Valve (303-08A Engine Emission Control - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
   Refer to: Exhaust Gas Recirculation (EGR) Valve (303-08B Engine Emission Control - 2.3L EcoBoost (199kW/270PS), Removal and Installation).
   

1. Disconnect the high-pressure fuel pump electrical connector.
   

1. NOTE: When removing or installing the high-pressure fuel pump insulator, spreading the openings will reduce the risk of damage.

   Remove the high-pressure fuel pump insulator.
   

1. Disconnect the electrical connector, then detach the wiring harness retainers and move out of the way.
   

1. Disconnect the high-pressure fuel pump fuel feed tube spring lock coupling.
   Refer to: Spring Lock Couplings (310-00A Fuel System - General Information - 2.0L EcoBoost (177kW/240PS) – MI4, General Procedures).
   

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.

   Remove the high-pressure fuel tube bracket bolts. Loosen the high-pressure fuel tube flare nuts, then disconnect, remove and discard the high-pressure fuel tube.
   

1. • Alternately loosen the high-pressure fuel pump bolts one complete revolution at a time. Remove and discard the high-pressure fuel pump bolts.
     
   • Remove the high-pressure fuel pump.
     

1. Remove and discard the high-pressure fuel pump O-ring seal.
   

1. Remove the high-pressure fuel pump tappet.
   

Installation

1. Inspect the high-pressure fuel pump roller 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 roller tappet drive lobe. Install new components as needed.
   

1. Remove the right front wheel and tire.
   Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
   

1. Remove the retainers, then position the fender splash shield aside.
   

1. If equipped, release the tabs and remove the crankshaft pulley cover.
   

1. If equipped, inspect the 3 crankshaft pulley cover tabs for damage, if damaged replace the crankshaft pulley cover.
   

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

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

   With the help of an assistant, using the crankshaft pulley bolt, turn the crankshaft until the high-pressure fuel pump cam lobe is at BDC .
   

1. If equipped.
   
   1. Align and insert 2 tabs of the crankshaft pulley cover into the open spaces between the ribs of the crankcase pulley.
      
   2. Press the third tab firmly into position until a snap is heard or felt.
      
   3. Verify that the crankshaft pulley cover is securely in place.
      

1. Position back the fender splash shield, then install the retainers.
   

1. Install the right front wheel and tire.
   Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
   

1. Apply clean engine oil to the high-pressure fuel pump drive unit bore, the drive lobe and the roller tappet.
   Refer to: Specifications (303-01A Engine - 2.0L EcoBoost (177kW/240PS) – MI4, Specifications).
   

1. NOTICE: The roller tappets roller goes down towards the camshaft.

   NOTE: Align the notch on the high-pressure fuel pump tappet and with the groove in the high-pressure fuel pump drive unit bore.

   Install the high-pressure fuel pump tappet.
   

1. Install a new high-pressure fuel pump O-ring seal. Apply clean engine oil to the new high-pressure fuel pump O-ring seal.
   Refer to: Specifications (303-01A Engine - 2.0L EcoBoost (177kW/240PS) – MI4, Specifications).
   

1. NOTE: Install new high-pressure fuel pump bolts.

   Install the high-pressure fuel pump and the new high-pressure fuel pump bolts. Alternately tighten each bolt one half revolution until seated, then tighten in the following 2 stages.
   Torque:
     Stage 1:  Tighten to: :   115 lb.in (13 Nm)
     Stage 2:  Tighten an additional: :   45°

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

   1. Install the new high-pressure fuel tube and the bracket bolts, then tighten the high pressure fuel tube flare nuts and the bracket bolts only finger tight at this stage.
      
   2. Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas.
      Torque:
         High pressure fuel tube flare nuts, :  
        Stage 1:  Tighten to: :   62 lb.in (7 Nm)
        Stage 2:  Tighten to: :   89 lb.in (10 Nm)
        Stage 3:  Tighten an additional: :   38°
         High-pressure fuel tube bracket bolts, tighten to: :   97 lb.in (11 Nm)

1. Connect the high-pressure fuel pump fuel feed tube spring lock coupling.
   Refer to: Spring Lock Couplings (310-00A Fuel System - General Information - 2.0L EcoBoost (177kW/240PS) – MI4, General Procedures).
   

1. Connect the electrical connector, then attach the wiring harness retainers.
   

1. NOTE: When removing or installing the high-pressure fuel pump insulator, spreading the openings will reduce the risk of damage.

   Install the high-pressure fuel pump insulator.
   

1. Connect the high-pressure fuel pump electrical connector.
   

1. Install the exhaust gas recirculation valve.
   Refer to: Exhaust Gas Recirculation (EGR) Valve (303-08A Engine Emission Control - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
   Refer to: Exhaust Gas Recirculation (EGR) Valve (303-08B Engine Emission Control - 2.3L EcoBoost (199kW/270PS), Removal and Installation).
   

1. Install the air cleaner outlet pipe.
   Refer to: Air Cleaner Outlet Pipe (303-12A Intake Air Distribution and Filtering - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
   

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 - 2.0L EcoBoost (177kW/240PS) – MI4, General Procedures).