Ford Fiesta Quiz
Engine

Fuel Pump. Removal and Installation

In this manual: Engine
Service Information — 27Suspension — 48Transmission — 9Brake System — 52Steering — 21Engine — 140Manual Transmission, Clutch, Transfer Case and Power Transfer Unit — 48Exhaust System — 6Fuel System — 21Climate Control System — 58Instrumentation and Warning Systems — 26Battery and Charging System — 20Infotainment Systems — 41Lighting — 29Power Distribution — 11Electronic Function Group — 30Body and Paint — 275Frame and Mounting — 3
29steps
~174min
5/5difficulty
010203040501310N·mlb·ft
Tightening torque found on this page
Done 0 of 29

Materials

Name Specification
Engine Oil — SAE 5W-20 — Semi-Synthetic Engine Oil
XO-5W20-Q1SP		 WSS-M2C945-B1

Removal

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

  1. Relieve the fuel system pressure.
    Refer to: Fuel System Pressure Relief (310-00B Fuel System – General Information) – 1.6 L EcoBoost (132 kW/180 L hp) – Sigma, General Procedures).
  2. Disconnect the battery.
    Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  3. Remove the ignition coil from the spark plugs.
    Refer to: Ignition Coil-On-Plug (303-07B Engine Ignition System - 1.6 L EcoBoost (132 kW/180 L PS) - Sigma, Removal and Installation).
  4. Remove the air cleaner outlet tube.
    Refer to: Air Cleaner Outlet Tube (303-12B Intake Air Distribution and Filtration – 1.6 L EcoBoost (132 kW/180 L hp) – Sigma, Removal and Installation).
    1. Quickly disconnect the positive crankcase ventilation (PCV) tube. Release the quick-release coupling. Release the hose retainer, loosen the clamp, and then remove the PCV tube.
      Refer to: Quick-Release Coupling (310-00B Fuel System - General Information. Information - 1.6 L EcoBoost (132 kW/180 L PS) - Sigma, General Procedures).
    1. Remove the TC inlet tube nut and stud, and loosen the TC air inlet tube clamp, then remove the TC inlet tube.
  6. Remove the high-pressure fuel pump heat shield.
    • Release the wiring harness retainers. Disconnect the FRP sensor electrical connector, the high-pressure fuel pump electrical connector, and the CMP electrical connector. Set the wiring harness aside.
    • Remove the ignition coil-on-plug mounting bracket lock nut. Loosen the captive remaining ignition coil-on-plug mounting bracket retainers, then remove the ignition coil-on-plug mounting bracket.
  8. Remove the ignition coil-on-plug mounting bracket insulator.
    1. Disconnect the fuel supply tube from the high-pressure fuel pump.
      Refer to: Spring-Lock Couplings (310-00B Fuel System - General Information. Information - 1.6 L EcoBoost (132 kW/180 L PS) - Sigma, General Procedures).
    1. Remove the high-pressure fuel pump fuel supply tube stud.
    1. Disconnect the high-pressure fuel pump fuel supply tube flare nut. Remove and discard the high-pressure fuel pump fuel supply tube.

  10. NOTICE: To relieve the fuel pressure in the high-pressure fuel system, wrap a shop towel around the high-pressure fuel pump fuel tube flare nut to absorb any residual fuel pressure while loosening the high-pressure fuel pump fuel tube flare nut.

    Disconnect the high-pressure fuel tube flare nuts. Remove and discard the high-pressure fuel tube.
  11. Remove the high-pressure fuel pump mounting bolts, then remove the high-pressure fuel pump.
  12. Remove and discard the high-pressure fuel pump O-ring.
  13. Remove the high-pressure fuel pump drive tappet.
  14. Inspect the high-pressure fuel pump drive tappet. If any spots or scoring are found, especially in the indicated areas, inspect the high-pressure fuel pump and the high-pressure fuel pump drive tappet cam lobe. Install new components as necessary.

Installation

  1. Remove the retainers and the cover.

  2. NOTICE: Rotate the crankshaft clockwise (CW) only, otherwise engine damage may occur.

    Rotate the camshaft until the high-pressure fuel pump cam lobe is at TDC.
  3. Lubricate the high-pressure fuel pump drive tappet and the high-pressure fuel pump drive assembly bore with clean engine oil.
    Material: Engine oil - SAE 5W-20 - synthetic engine oil / XO-5W20-Q1SP (WSS-M2C945-B1)
  4. Install the high-pressure fuel pump and loosely install the high-pressure fuel pump bolts. Alternately tighten each bolt one-half turn at a time until seated. Tighten the high-pressure fuel pump bolts.
    Torque: 115 lb-in (13 N·m)
  5. Install the cover, then install and tighten the cover retainers.
    Torque: 27 lb-in (3 N·m)
  6. Tighten the high-pressure fuel tube flare nuts in the following 3 steps.
    Torque:
    Step 1: 15 lb-ft (21 N·m)
    Step 2: Wait 5 minutes
    Step 3: 15 lb-ft (21 N·m)
    1. Install a new high-pressure fuel pump fuel supply tube and high-pressure fuel pump fuel supply tube stud. Finger-tighten.
    1. Tighten the high-pressure fuel pump fuel supply tube stud.
      Torque: 62 lb-in (7 N·m)
    1. Tighten the high-pressure fuel pump fuel supply tube flare nut in the following 3 steps.
      Torque:
      Step 1: 15 lb-ft (21 N·m)
      Step 2: Wait 5 minutes
      Step 3: 15 lb-ft (21 N·m)
    1. Connect the high-pressure fuel pump fuel supply tube.
      Refer to: Spring-Lock Couplings (310-00B Fuel System - General Information. Information - 1.6 L EcoBoost (132 kW/180 L PS) - Sigma, General Procedures).
  8. Install the ignition coil-on-plug mounting bracket insulator.

    1. Install the ignition coil-on-plug mounting bracket, then install and tighten the ignition coil-on-plug mounting bracket bolts.
      Torque:
      Step 1: 89 lb-in (10 N·m)
      Step 2: 53 lb-in (6 N·m)
    1. Install the wiring harness, then attach the wiring harness retainers. Connect the FRP sensor electrical connector, the high-pressure fuel pump electrical connector, and the CMP electrical connector.
  10. Install the high-pressure fuel pump insulator.
    1. Install the TC inlet tube.
    1. Install and tighten the TC inlet tube stud and lock nut.
      Torque: 44 lb-in (5 N·m)
    1. Tighten the TC intake tube clamp.
      Torque: 44 lb-in (5 N·m)
    1. Install the crankcase ventilation tube and clamp.
    1. Connect the crankcase ventilation tube quick-connect coupling.
      Refer to: Quick Connect Coupling (310-00B Fuel System - General Information). Information - 1.6 L EcoBoost (132 kW/180 L PS) - Sigma, General Procedures).
    1. Install the hose retainer.
      Torque: 44 lb-in (5 N·m)
  12. Install the air cleaner outlet pipe.
    Refer to: Air Cleaner Outlet Pipe (303-12B Intake Air Distribution and Filtration — 1.6 L EcoBoost (132 kW/180 L hp) — Sigma, Removal and Installation).
  13. Install the ignition coil on the spark plugs.
    Refer to: Ignition Coil on Spark Plug (303-07B Engine Ignition System - 1.6 L EcoBoost (132 kW/180 L PS) - Sigma, Removal and Installation).
  14. Connect the battery.
    Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  15. Pressurize the fuel system.
    Refer to: Fuel System Pressure Release (310-00B Fuel System - General Information). Information - 1.6 L EcoBoost (132 kW/180 L PS) - Sigma, General Procedures).

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