Lincoln Navigator: Fuel Charging and Controls - 3.5L EcoBoost (272kW/370PS) / High-Pressure Fuel Pump. Removal and Installation

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 (100-02 Jacking and Lifting, Description and Operation).
   

1. Remove the engine appearance cover retainers, release the engine appearance cover from the rear retaining tabs on the intake manifold, then remove the engine appearance cover.
   

1. Release the fuel system pressure.
   Refer to: Fuel System Pressure Release (310-00 Fuel System - General Information - 3.5L EcoBoost (272kW/370PS), General Procedures).
   

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

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

1. 1. Disconnect the secondary latch and position out of the way.
      
   2. Disconnect the spring lock coupling, then disconnect the high-pressure fuel pump supply line.
      Refer to: Spring Lock Couplings (310-00 Fuel System - General Information - 3.5L EcoBoost (272kW/370PS), General Procedures).
      

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

   2. Disconnect the flare nuts, then remove and discard the high-pressure fuel tube.
      

1. Remove the high-pressure fuel pump bolts by alternately loosening the bolts one complete revolution at a time, then remove the high-pressure fuel pump.
   

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

1. Remove the roller tappet.
   

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

1. Remove any dirt or foreign material from the high-pressure fuel pump bolt holes.
   

Installation

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

   NOTICE: The drive lobe for the high-pressure fuel pump must be at BDC (bottom dead center) 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 drive lobe is at BDC .
   

1. Inspect the cam cover seal, clean and replace it as needed. Lubricate the seal with clean engine oil.
   Refer to: Specifications (303-01 Engine - 3.5L EcoBoost (272kW/370PS)) .
   

1. Apply clean engine oil to the high-pressure fuel pump mounting pedestal bore, the drive lobe and all of the roller tappet.
   Refer to: Specifications (303-01 Engine - 3.5L EcoBoost (272kW/370PS)) .
   

1. NOTICE: The roller tappet's roller goes down towards the camshaft.

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

   Install the roller tappet.
   

1. Install a new high-pressure fuel pump O-ring seal. Lubricate with clean engine oil.
   Refer to: Specifications (303-01 Engine - 3.5L EcoBoost (272kW/370PS)) .
   

1. 1. Install the high-pressure fuel pump and the bolts. Tighten the fuel high-pressure fuel pump bolts in the following 5 stages.
      Torque:
        Stage 1:  Finger tighten the bolts :   0 lb.in (0 Nm)
        Stage 2:  Tighten bolt 1 :   1 turn(s)
        Stage 3:  Tighten bolt 2 :   1 turn(s)
        Stage 4:  Repeat stages 2 and 3, until reaching :   177 lb.in (20 Nm)
        Stage 5:  Tighten bolts 1 and 2, in sequence an additional :   45°

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

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

      Install the high-pressure fuel tube and tighten the flare nuts finger tight.
      

   3. NOTICE: In stage 3, if the torque required to tighten any flare nut on the new high-pressure fuel tube reaches or exceeds 55 lb.ft (75 Nm), then that high pressure fuel tube must be discarded and replaced with another new high-pressure fuel tube.

      Tighten the high-pressure fuel tube flare nuts, in the following 3 stages.
      Torque:
        Stage 1:  Tighten to :   80 lb.in (9 Nm)
        Stage 2:  Tighten to :   89 lb.in (10 Nm)
        Stage 3:  Tighten an additional :   38°

1. NOTICE: The spring lock coupling must be installed onto the fuel tube end along the centerline. The assembly is complete when the tube end bottoms out on the spring lock coupling with an audible click / snap feel. Correct assembly should be verified by pulling back on the spring lock coupling end.

   1. Connect the high-pressure fuel pump supply line, then connect the spring lock coupling. Verify the correct assembly by pulling back on the spring lock coupling end.
      Refer to: Spring Lock Couplings (310-00 Fuel System - General Information - 3.5L EcoBoost (272kW/370PS), General Procedures).
      
   2. Install the secondary latch.
      

1. 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 (310-00 Fuel System - General Information - 3.5L EcoBoost (272kW/370PS), General Procedures).
   

1. Install the engine appearance cover into the rear retain tabs on the intake manifold, then install and tighten the engine appearance cover retainers.
   Torque: 97 lb.in (11 Nm)