Installation Procedure
Fuel Injector Bushing (1) - Install NEW
- NOTE:
Use a lint free swab to apply the lubrication to the O-ring before installation.
Holding the largest diameter/body of the fuel injector (2), insert the injector assembly (2) into the fuel rail. Ensure correct orientation of the electrical connector.
- Fuel Injector Retainer (1) - Install NEW
- NOTE:
When installing the connectors, ensure the connector position assurance (CPA) tab is engaged for each connector.
Install the fuel injector wiring harness (2) and connect to appropriate fuel injectors and fuel pressure sensor.
- Install NEW fuel injector wiring harness tie straps (1).
- NOTE:
DO NOT use any type of lubricant when installing the NEW fuel injector nozzle housing seals on the fuel injector tip.
Install EN-51955-1 Long Protector (1) onto the fuel injector tip, covering the first recessed area closest to the tip. Place a NEW fuel injector nozzle housing seal (2) on EN-51955-1 Long Protector (1).
- Using EN-51955-4 Pusher (3), install the fuel injector nozzle housing seal (2) into the recessed area (4) of the fuel injector, then remove the EN-51955-1 Long Protector.
- Compress the fuel injector nozzle housing seal (2) using EN-51955-3 Pre-Sizer (5).
- Using EN-51955-5 Sizer (6), resize the fuel injector nozzle housing seal.
- Install EN-51955-2 Short Protector (7) onto the fuel injector tip. Place a second NEW fuel injector nozzle housing seal (8) on EN-51105-2 Short Protector (7).
- Using EN-51955-4 Pusher (3), install the fuel injector nozzle housing seal (8) into the remaining recessed area (9) of the fuel injector, then remove EN-51105-2 Short Protector.
- Compress the fuel injector nozzle housing seal (8) using EN-51955-3 Pre-Sizer (5).
- Using EN-51955-5 Sizer (6), resize the fuel injector nozzle housing seal.
- CAUTION:
During the installation of the fuel rail and injector assembly, ensure that the fuel injectors are positioned straight into the injector opening. Failure to follow this caution can tilt or bend the injectors and could cause leaks or malfunction after installation.
NOTE:Hand place the fuel injection fuel rail into the position on the cylinder head.
Fuel Injection Fuel Rail (1) - Move into position
- Fuel Injection Fuel Rail Bolt (2) - Install and hand tighten [4x]
- Tighten the two outer fuel injection fuel rail bolts by alternating in steps of 1/2 turn, until the fuel injection fuel rail (1) is fully seated.
- Fuel Injection Fuel Rail Bolt (2) - Tighten [4x] - Fastener Specifications
- Electrical Connector (3) - Connect [3x]
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise canceling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
Fuel Injection Fuel Rail Noise Shield (1) - Install
Fuel Feed Intermediate Pipe (2) - Install NEW
- Nut @ Fuel Feed Intermediate Pipe - Install and hand tighten [2x]
- Fuel Injection Fuel Feed Pipe Bracket Bolt (1) - Install and tighten - Fastener Specifications
- CAUTION:
Refer to Component Fastener Tightening Caution .
Nut @ Fuel Feed Intermediate Pipe (1) - Tighten [2x] - Fastener Specifications
Engine Coolant Flow Control Valve Seal (2) - Install NEW
- Engine Coolant Flow Control Valve (1) - Install
Engine Coolant Flow Control Valve Bolt (1) - Install [5x] - Fastener Specifications
Electrical Connector (2) @ Engine Coolant Flow Control Valve - Connect [2x]
- Electrical Connector (1) @ Engine Coolant Temperature Sensor - Connect
Engine Coolant Thermostat Housing Inlet Pipe (3) @ Engine Coolant Flow Control Valve - Install
- Exhaust Manifold Outlet Pipe (2) @ Engine Coolant Flow Control Valve - Install
- Hose Clamp (1) - Engage [2x] - Hose Clamp Replacement Guidelines - Spring Type
Engine Oil Cooler Coolant Inlet Hose (4) @ Engine Coolant Flow Control Valve - Install
- Radiator Inlet Hose (3) @ Engine Coolant Flow Control Valve - Install
- Thermostat Bypass Pipe (2) @ Engine Coolant Flow Control Valve - Install
- Hose Clamp (1) - Engage [3x] - Hose Clamp Replacement Guidelines - Spring Type
Crankcase Vent Passage Seal (4) - Install NEW
- Intake Manifold Gasket (3) - Install NEW [4x]
Intake Manifold (1) - Install
Intake Manifold Bolt (1) - Install and tighten [6x] - Fastener Specifications
Retainer (1) - Install
Charge Air Cooler Outlet Air Tube (2) @ Throttle Body (3) - Install
- Retainer Spring (1) - Engage
Upper Intake Manifold Cover (1) - Install
Intake Manifold Cover Stud (2) - Install and tighten [3x] - Fastener Specifications
- Intake Manifold Cover Bolt (1) - Install and tighten [2x] - Fastener Specifications
Evaporative Emission Canister Purge Pump (2) - Install
- Evaporative Emission Canister Purge Pump Bolt (1) - Install and tighten [3x] - Fastener Specifications
Engine Wiring Harness (4) - Reposition
- Retainer (3) - Install [4x]
- Electrical Connector (2) - Connect [2x]
- Engine Wiring Harness Bolt (1) - Install and tighten - Fastener Specifications
Throttle Body Electrical Connector (1) - Connect
Radiator Surge Tank Inlet Hose (3) - Reposition
- Retainer (2) - Install [3x]
- Evaporative Emission Canister Purge Tube (1) - Connect
Evaporative Emission Pipe (2) - Connect
- Fuel Feed Pipe (1) - Connect
- NOTE:
Ensure the intake manifold cover insulator retainers fully engage the intake manifold cover studs.
Intake Manifold Cover Insulator (1) - Install
Intake Manifold Cover Bolt (1) - Install and tighten - Fastener Specifications
Intake Manifold Cover (1) @ Upper Intake Manifold Bracket (2) - Install
Push down on the front of the intake manifold cover (2).
- Intake Manifold Cover Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Install the oil fill cap.
Oil Level Indicator Tube (1) - Install
Oil Level Indicator Tube Bracket Bolt (1) - Install and tighten - Fastener Specifications
Oil Level Indicator (1) - Install
- Connect the battery negative cable. Battery Negative Cable Disconnection and Connection
- Fill the cooling system. Cooling System Draining and Filling (L3B Static Fill) , or Cooling System Draining and Filling (L3B GE 47716)
- Pressurize the fuel system and inspect for leaks.
- Turn ON the ignition with the engine OFF for 2 seconds.
- Turn OFF the ignition for 10 seconds.
- Turn ON the ignition with the engine OFF.
- Inspect for fuel leaks.
- Perform the intake system learned values reset. Intake System Learned Values Reset
- Perform the throttle body idle air flow compensation reset. Throttle Body Idle Air Flow Compensation Reset
Ensure the fuel injector retainer is properly installed. Failure to completely install the retainers may degrade fuel injection system performance or cause system malfunction.
Install the four fuel injection fuel rail bolts hand tight only, DO NOT apply any torque.
Refer to Fastener Caution .