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Home >> Chevrolet >> 2016 >> Volt Premier >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls And Fuel - 1.5L (L3A) - Repair Instructions >> Repair Instructions >> Fuel Injection Pump Replacement >> Installation Procedure

Installation Procedure

    Fig 1: Gauge
    GM3824669Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The camshaft must be in the base circle position before the high pressure fuel pump is installed.

  1. Install the EN-51365  Gauge (1).
  2. Use EN-51365  Gauge and rotate the crankshaft until the special tool is flush with the cylinder head. This indicates the camshaft lobe is at base circle position.
  3. Remove the EN-51365  Gauge.
    4. Fig 2: Fuel Injection Pump, Bolts, Gasket, Electrical Connector And Valve Lifter Follower
    GM4091372Courtesy of GENERAL MOTORS COMPANY
  4. Lubricate the valve lifter follower (1) with a bit engine oil.
  5. Install Valve Lifter Follower (1)
  6. Ensure that the guide pin on the follower is aligned with the groove in the fuel pump bore.
  7. Install a NEW Fuel Injection Pump Gasket (2).
  8. Install Fuel Injection Pump (3)
  9. Connect the electrical connector (5).
    10. CAUTION:

    Alternately hand-tighten the fuel pump bolts one turn at a time until the pump is fully seated. Trying to draw down the pump without even side-to-side tightening may result in pump plunger damage.

    CAUTION:

    Refer to Fastener Caution

  10. Install and tighten Fuel Injection Pump Bolt (4, 6) to 25 N.m (18 lb ft)
    11. Fig 3: Engine Wiring Harness Bracket, Bolts, Ground Cable And Electrical Connector
    GM4091309Courtesy of GENERAL MOTORS COMPANY
  11. Install Engine Wiring Harness Bracket (1)
  12. Install and tighten Engine Wiring Harness Bracket Bolt (3) (Qty: 2) @ Engine Wiring Harness Bracket to 25 N.m (18 lb ft)
  13. Connect the electrical connector (2).
  14. Install Ground Cable (5)
  15. Install and tighten Bolt (4) to 10 N.m (89 lb in)
    16. Fig 4: Heater Outlet Hose And Clamp
    GM4091334Courtesy of GENERAL MOTORS COMPANY
  16. Install Heater Outlet Hose (1)
  17. Install Heater Outlet Hose Clamp (2) using BO-38185  Pliers.
    18. Fig 5: Engine Wiring Harness And Bracket
    GM4297788Courtesy of GENERAL MOTORS COMPANY
  18. Install Engine Wiring Harness (1) @ Engine Wiring Harness Bracket (2)
    19. Fig 6: Fuel Feed Front Pipe And Fuel Injection Pump
    GM4091024Courtesy of GENERAL MOTORS COMPANY
  19. Install Fuel Feed Front Pipe (2)
  20. Remove all EN-6015  plugs from the connections.
  21. Connect Fuel Feed Front Pipe (2) @ Fuel Injection Pump (1)
    22. Fig 7: Fuel Feed Intermediate Pipe, Bolt And Nuts
    GM4091049Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The Fuel Feed Intermediate Pipe must not be reused, otherwise leakage may occur.

  22. Install a NEW fuel feed intermediate pipe (6).
  23. Hand tighten the fuel feed intermediate pipe nut (2) to the fuel injection rail (3).
  24. Hand tighten the fuel feed intermediate pipe nut (5) to the fuel injection pump (4).
  25. Tighten the 2 nuts (2, 5) to 30 N.m (22 lb ft).
  26. Install the fuel feed intermediate pipe bracket bolt (3) and tighten to 10 N.m (89 lb in).
    27. Fig 8: Air Cleaner Resonator Bracket, Bolt And Wiring Harness Clip
    GM4091051Courtesy of GENERAL MOTORS COMPANY
  27. Install the air cleaner resonator bracket (2).
  28. Install the air cleaner resonator bracket bolt (1) and tighten to 9 N.m (80 lb in).
  29. Install Wiring Harness Clip (3)
  30. Install Air Inlet Grille Panel. Refer to Air Inlet Grille Panel Replacement
  31. Install Intake Manifold Cover. Refer to Intake Manifold Cover Replacement
  32. Install Air Cleaner Outlet Duct. Refer to Air Cleaner Outlet Duct Replacement 
  33. Connect Battery Negative Cable. Refer to Battery Negative Cable Disconnection and Connection
  34. Fill the cooling system. Refer to Cooling System Draining and Filling
  35. When the replacement is completed, use a scan tool to perform the appropriate reset functions. Refer to Control Module References .
    36. WARNING:

    Fuel escapes - observe safety measures and national legislation. Failure to comply could result in personal injury.

    NOTE:

    Ensure that all work at the engine is finished.

  36. Perform a fuel injection system leak test.
    1. Start the engine.
    2. Check the fuel system for leaks.
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