2008 F-Super Duty Workshop Manual

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1 Page 1 of 13 SECTION C: Fuel Charging and Controls 6.4L Diesel 2008 F-Super Duty Workshop Manual REMOVAL AND INSTALLATION Procedure revision date: 03/04/2009 Fuel Injection Pump High Pressure, Body Off Printable View (1860 KB) Special Tool(s) Caps, Fuel System Dial Indicator Gauge with Holding Fixture (TOOL-4201-C) Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool Material Item Specification RTV Silicone Sealant TA-31 Glow Plug Module Heat Shield Item Part Number Description 1 Glow plug module heat shield pushnuts 2 Glow plug module heat shield High-Pressure Fuel Injection Pump Heat Shields

2 Page 2 of 13 Item Part Number Description 1 W Engine-to-body ground wire nut 2 19A095 Engine-to-body ground wire 3 W RH high-pressure fuel injection pump heat shield nut 4 W RH high-pressure fuel injection pump heat shield bolts (2 required) 5 RH high-pressure fuel injection pump heat shield bolt 6 9G478 RH high-pressure fuel injection pump heat shield 7 W LH high-pressure fuel injection pump heat shield nuts (3 required) Fuel tube bracket 9 9G478 LH high-pressure fuel injection pump heat shield Fuel Rail Supply Tubes

Page 3 of 13 Item Part Number Description 1 High-pressure fuel injection pump electrical connector (part of 9F759) 2 Fuel injector return tube fitting (part of 9C273) 3 W300002 Fuel rail supply tube

3 Page 3 of 13 Item Part Number Description 1 High-pressure fuel injection pump electrical connector (part of 9F759) 2 Fuel injector return tube fitting (part of 9C273) 3 W Fuel rail supply tube bracket bolts (2 required) 4 9A332 LH fuel rail supply tube 5 9A332 RH fuel rail supply tube High-Pressure Fuel Injection Pump Supply and Return Tubes Item Part Number Description 1 W Fuel injection pump supply tube bracket nuts (2 required) 2 W Fuel tube-to-high-pressure fuel injection pump nuts (2 required) 3 W Fuel tube-to-high-pressure fuel injection pump washers (2 required) 4 9C330 Fuel injection pump supply tube 5 9D309 Fuel injection pump-to-fuel cooler return tube

4 Page 4 of 13 High-Pressure Fuel Injection Pump Cover NOTE: Turbocharger assembly removed from art for clarity. Item Part Number Description 1 W High-pressure fuel injection pump cover bolts (5 required) 2 9A413 High-pressure fuel injection pump cover High-pressure fuel injection pump cover press-in-place gasket 4 Volume control valve electrical connector (part of 6619) 5 Pressure control valve electrical connector (part of 6619) High-pressure fuel injection pump cover gasket High-Pressure Fuel Injection Pump NOTE: Turbocharger assembly removed from art for clarity.

5 Page 5 of 13 Item Part Number Description 1 W High-pressure fuel injection pump bolts (3 required) 2 9A543 High-pressure fuel injection pump 3 W High-pressure fuel injection pump gear bolt (LH thread) 4 W High-pressure fuel injection pump gear washer 5 9F589 High-pressure fuel injection pump gear Removal NOTE: It is recommended that this component be serviced with the vehicle body removed. If the body cannot be removed, refer to Fuel Injection Pump High Pressure, Body On in this section. 1. WARNING: Do not work on the fuel system until the pressure has been released and the engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in serious personal injury. Shut the engine off and wait until the engine is cool or 5 minutes, whichever is longer, to allow the high-pressure fuel system pressure to bleed off and the fuel to cool. 2. Remove the turbocharger inlet pipes. Carry out the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) Turbocharger Inlet Pipes 6.4L, Body Off procedure. For additional information, refer to Section Remove the 3 pushnuts and the glow plug module heat shield. Discard the pushnuts. 4. Remove the 3 RH high-pressure fuel injection pump heat shield bolts.

6 Page 6 of Remove the 2 RH high-pressure fuel injection pump heat shield nuts and position the engine-to-body ground wire aside. Remove the RH high-pressure fuel injection pump heat shield. 6. Remove the 3 nuts, the fuel tube bracket and the LH high-pressure fuel injection pump heat shield. 7. Remove the 2 fuel rail supply tube bracket bolts. 8. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes. NOTE: LH side shown, RH side similar. Remove and discard the fuel rail supply tubes. 9. Disconnect the high-pressure fuel injection pump electrical connector.

7 Page 7 of NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes. Disconnect the fuel injector return tube fitting from the check valve. 11. Loosen the 2 high-pressure fuel injection pump supply tube bracket nuts. 12. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes. NOTE: Use a back-up wrench to prevent the fittings in the high-pressure fuel pump from turning. Remove the fuel tube-to-high-pressure fuel injection pump nuts and the copper sealing washers. Remove the fuel injection pump-to-fuel cooler return tube and position the fuel supply tube aside. Discard the copper sealing washers. 13. NOTE: Rotate the cover to the right when removing the cover. Remove the 5 bolts and the high-pressure fuel injection pump cover. 14. Remove and discard the press-in-place gasket from the high-pressure fuel injection pump cover.

Page 8 of 13 15. Disconnect the pressure control valve and volume control valve electrical connectors. 16. NOTE: Use a thin gasket scraper to separate the gasket from the crankcase.

8 Page 8 of Disconnect the pressure control valve and volume control valve electrical connectors. 16. NOTE: Use a thin gasket scraper to separate the gasket from the crankcase. Remove and discard the high-pressure fuel injection pump cover gasket. 17. Position the Dial Indicator Gauge and Holding Fixture and check the high-pressure fuel injection pump drive gear backlash. 18. Remove the 3 bolts and the high-pressure fuel injection pump. 19. NOTE: The high-pressure fuel injection pump drive gear bolt is a LH thread. If a new pump is being installed, remove the bolt, the washer and the high-pressure fuel injection pump gear.

Page 9 of 13 Installation 1. NOTICE: The protruding hub of the high-pressure fuel injection pump drive gear must be facing the high-pressure fuel injection pump.

9 Page 9 of 13 Installation 1. NOTICE: The protruding hub of the high-pressure fuel injection pump drive gear must be facing the high-pressure fuel injection pump. Failure to install the gear correctly will result in engine damage. NOTE: The high-pressure fuel injection pump drive gear bolt is a LH thread. NOTE: The high-pressure fuel injection pump gear bolt will not be tightened at this time. If a new pump is being installed, install the high-pressure fuel injection pump drive gear, washer and bolt. 2. Install the high-pressure fuel injection pump and the 3 bolts. Tighten to 61 Nm (45 lb-ft). 3. NOTE: The high-pressure fuel injection pump gear bolt has a LH thread. NOTE: Use a tool such as a Snap-On FRDHM15 torque adapter, or equivalent, to tighten the bolt. If a new high-pressure fuel pump has been installed, tighten the gear bolt. Calculate the correct torque wrench setting for the following torque. Refer to the Torque Wrench Adapter Formulas in the Appendix. Using a torque adapter, tighten to 77 Nm (57 lb-ft). 4. Using the Dial Indicator Gauge with Holding Fixture, check the high-pressure fuel injection pump drive gear backlash.

Page 10 of 13 5. Clean the cover mounting surface and apply a dime-sized bead of sealant at the seams. 6.

10 Page 10 of Clean the cover mounting surface and apply a dime-sized bead of sealant at the seams. 6. NOTICE: Inspect the volume control valve and the pressure control valve electrical connectors for damage or obstructions at the connector and mating high-pressure fuel injection pump connector. Verify that the connectors are completely latched to the valve housings or engine damage may occur. Install a new high-pressure fuel injection pump cover gasket. Connect the pressure control valve and volume control valve electrical connectors. 7. Install a new press-in-place gasket in the high-pressure fuel injection pump cover. 8. NOTE: Do not remove the Fuel System Caps from the high-pressure fuel injection pump until the fuel tubes are being installed. Install the high-pressure fuel injection pump cover and the 5 bolts. Tighten to 13 Nm (115 lb-in). 9. NOTE: Use a back-up wrench on the high-pressure fuel injection pump fittings. Install new copper sealing washers, the fuel tubes and the nuts to the high-pressure fuel injection pump. Tighten to 38 Nm (28 lb-ft).

11 Page 11 of Tighten the 2 fuel injection pump supply tube bracket nuts. Tighten to 11 Nm (97 lb-in). 11. Connect the fuel injector return tube fitting to the check valve. Tighten to 28 Nm (21 lb-ft). 12. Connect the high-pressure fuel injection pump electrical connector. 13. NOTE: LH side shown, RH side similar. Install the new fuel rail supply tubes one at a time in the following sequence. 1. Remove only the Fuel System Caps from the fuel rail supply tube openings being serviced. 2. NOTE: Support the tubes while hand snugging the nut to make sure of correct assembly of the joints. Position the new fuel rail supply tubes between the high-pressure fuel injection pump and high-pressure fuel rail. Fully hand start and seat the 4 fuel rail supply tube fittings onto the high-pressure fuel injection pump and high-pressure fuel rails. 3. Snug the 4 fuel rail supply tube fittings. Calculate the correct torque wrench setting for the following torque. Refer to the Torque Wrench Adapter Formulas in the Appendix. Using a torque adapter, tighten to 2 Nm (18 lb-in). 4. Pre-tighten the 4 fuel rail supply tube fittings. Calculate the correct torque wrench setting for the following torque. Refer to the Torque Wrench Adapter Formulas in the Appendix. Using a torque adapter, tighten to 12 Nm (106 lb-in). 5. NOTE: Place a visible mark with a permanent marker on the 4 fuel rail supply tube threaded connections. Turning the fuel injector supply tube nuts one flat of the fitting is equal to 60 degrees. Final-tighten the 4 fuel rail supply tube fittings. Tighten the 4 fuel rail supply tube fittings 60 degrees.

12 Page 12 of Install the 2 fuel rail supply tube bracket bolts. Tighten to 13 Nm (115 lb-in). 15. NOTICE: Failure to correctly install the heat shield may result in engine damage. Install the LH high-pressure fuel injection pump heat shield, the fuel tube bracket and the 3 nuts. Tighten to 7 Nm (62 lb-in). 16. Install the RH fuel pump heat shield and position the engine-to-body ground wire. Install the 2 nuts. Tighten to 13 Nm (115 lb-in). 17. Install the 3 high-pressure fuel injection pump heat shield bolts. Tighten to 13 Nm (115 lb-in). 18. Install the glow plug module heat shield and 3 new pushnuts.

13 Page 13 of Install the turbocharger inlet pipes. Carry out the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) and Turbocharger Inlet Pipes 6.4L Diesel, Body Off procedure. For additional information, refer to Section Bleed the low-pressure and high-pressure fuel system. For additional information, refer to Section NOTE: Clearing the DTCs or Keep Alive Memory (KAM) does not reset the adaptive values in the PCM. If the high-pressure fuel injection pump was replaced, clear the fuel injector adaptive tables from the PCM, using the scan tool. For additional information, refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.

REMOVAL AND INSTALLATION

303-04C-1 REMOVAL AND INSTALLATION Fuel Injectors Special Tool(s) Caps, Fuel System 310-158 Special Tool(s) 303-04C-1 Holding Rack, Fuel Injector 303-D114 (D94T-9000-E1) Cups, Fuel Injector 303-1261 Tool,