Gasoline engines with direct fuel injection (GDI engines) - Installation of the high pressure fuel pump to the engine

This document specifies dimensions required for the installation and integration of the high pressure fuel pump in gasoline (GDI) engines. The location of the fuel connections and the dimensions of the pump outside shape are not defined since they vary according to the manufacturer of the pump and to the particular application.

Moteur à essence à injection directe (moteurs GDI) — Installation de la pompe d'injection de carburant à haute pression sur le moteur

General Information

Status
Published
Publication Date
19-Aug-2018
Current Stage
9092 - International Standard to be revised
Start Date
28-Oct-2024
Completion Date
13-Dec-2025

Relations

Effective Date
07-Jan-2025

Overview

ISO 21042:2018 provides dimensional and tolerance guidance for the installation and integration of the high-pressure fuel pump in gasoline direct injection (GDI) engines. The standard focuses on the engine-side flange interface and mounting characteristics required for robust, repeatable assembly. It does not prescribe the external pump housing shape or the precise location of fuel connections, which vary by pump supplier and application.

Why this matters: correct flange dimensions, bolt patterns and connector compatibility reduce integration risk, improve interchangeability between suppliers and simplify service and assembly procedures.

Key Topics

  • Engine flange interface and tolerances

    • Preferred bore and mounting details include D1 = 35H7 and options for D2 = 32H7 or 26H7 where applicable.
    • Bolt size: preferred M8 (M6 optional) and common mounting pitch values (e.g., 66 mm preferred; alternatives listed).
    • Bore depth and effective screw depth: minimum bore depth values are given (e.g., 12 mm min.), and a practical minimum effective screw depth of around 15 mm is recommended to match material quality and bolt size-final values to be agreed between pump supplier and engine manufacturer.
  • Pump intrusion / height and guiding

    • The document addresses the pump intrusion (lower housing height) and guiding cylinder for the tappet to ensure correct mechanical engagement with the camshaft lobe.
  • Low-pressure connector requirements

    • Low-pressure inlet tube diameters: 8 mm (5/16") or 9.5 mm (3/8").
    • Connectors shall comply with ISO 13948-2:2016 (type C) or SAE J2044. If SAE J2044 is used, bead radii must avoid sharp edges and ensure a minimum 0.25 mm annular flat for the female connector.
  • High-pressure connector requirements

    • High-pressure connections shall comply with ISO 18418-1 or ISO 2974.
  • Lubrication on assembly

    • Ensure the pump plunger and tappet are supplied with lube oil during assembly. If assembled top-down, provide a drain or evacuation feature to remove oil and debris.

Applications

  • Engine designers integrating a cam-driven high-pressure pump into cylinder heads.
  • Pump suppliers preparing mounting interfaces for OEM engines to achieve interchangeability.
  • Manufacturing and service teams needing clear dimensional references for assembly, inspection and maintenance.

Practical benefits: reduced rework at prototype and production stages, improved parts interchangeability, and clearer supplier–OEM agreements on interface design.

Related Standards

  • ISO 18418-1 - Medium pressure fuel supply connections (GDI)
  • ISO 2974 - 60° female cones for high-pressure injection components
  • ISO 13948-2:2016 - Low-pressure (push-on) connections
  • SAE J2044 - Quick connect coupling for liquid fuel systems
  • ISO 18418-2 and ISO 19724 - related fuel system assembly and cleanliness guidance

For implementation, refer to the full ISO 21042:2018 document and coordinate final dimensions and material suitability between pump suppliers and engine manufacturers.

Standard

ISO 21042:2018 - Gasoline engines with direct fuel injection (GDI engines) — Installation of the high pressure fuel pump to the engine Released:8/20/2018

English language
5 pages
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Frequently Asked Questions

ISO 21042:2018 is a standard published by the International Organization for Standardization (ISO). Its full title is "Gasoline engines with direct fuel injection (GDI engines) - Installation of the high pressure fuel pump to the engine". This standard covers: This document specifies dimensions required for the installation and integration of the high pressure fuel pump in gasoline (GDI) engines. The location of the fuel connections and the dimensions of the pump outside shape are not defined since they vary according to the manufacturer of the pump and to the particular application.

This document specifies dimensions required for the installation and integration of the high pressure fuel pump in gasoline (GDI) engines. The location of the fuel connections and the dimensions of the pump outside shape are not defined since they vary according to the manufacturer of the pump and to the particular application.

ISO 21042:2018 is classified under the following ICS (International Classification for Standards) categories: 43.060.40 - Fuel systems. The ICS classification helps identify the subject area and facilitates finding related standards.

ISO 21042:2018 has the following relationships with other standards: It is inter standard links to ISO/FDIS 21042. Understanding these relationships helps ensure you are using the most current and applicable version of the standard.

ISO 21042:2018 is available in PDF format for immediate download after purchase. The document can be added to your cart and obtained through the secure checkout process. Digital delivery ensures instant access to the complete standard document.

Standards Content (Sample)


INTERNATIONAL ISO
STANDARD 21042
First edition
2018-09
Gasoline engines with direct
fuel injection (GDI engines) —
Installation of the high pressure fuel
pump to the engine
Moteur à essence à injection directe (moteurs GDI) — Installation de
la pompe d'injection de carburant à haute pression sur le moteur
Reference number
©
ISO 2018
© ISO 2018
All rights reserved. Unless otherwise specified, or required in the context of its implementation, no part of this publication may
be reproduced or utilized otherwise in any form or by any means, electronic or mechanical, including photocopying, or posting
on the internet or an intranet, without prior written permission. Permission can be requested from either ISO at the address
below or ISO’s member body in the country of the requester.
ISO copyright office
CP 401 • Ch. de Blandonnet 8
CH-1214 Vernier, Geneva
Phone: +41 22 749 01 11
Fax: +41 22 749 09 47
Email: copyright@iso.org
Website: www.iso.org
Published in Switzerland
ii © ISO 2018 – All rights reserved

Contents Page
Foreword .iv
Introduction .v
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 1
4 Dimensions and tolerances . 1
4.1 General . 1
4.2 High pressure pump interface . 2
4.3 Low pressure connector . 4
4.4 High pressure connector . 4
4.5 Lubrication . 4
Bibliography . 5
Foreword
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This document was prepared by Technical Committee ISO/TC 22, Road vehicles, Subcommittee SC 34,
Propulsion, powertrain, and powertrain fluids.
Any feedback or questions on this document should be directed to the user’s national standards body. A
complete listing of these bodies can be found at www .iso .org/members .html.
iv © ISO 2018 – All rights reserved

Introduction
The motor vehicle industry is increasingly being pressured by the world's regulators to improve
fuel consumption whilst reducing exhaust emissions (particularly CO emissions). The challenge for
automotive engineers is to balance the trade-offs between the t
...

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