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Home >> Chevrolet >> 2018 >> Volt Premier >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls And Fuel System- - 1.5L (L3A) - Repair Instructions >> Repair Instructions >> Fuel Injection Pump Replacement >> Installation Procedure

Installation Procedure

  1. Before continuing, lubricate the cylinder head bore with clean engine oil. Adhesives, Fluids, Lubricants, and Sealers
  2. GM4864730Courtesy of GENERAL MOTORS COMPANY

    Lubricate the valve lifter follower (1) with clean engine oil and install it into the cylinder head bore. Adhesives, Fluids, Lubricants, and Sealers

    3. NOTE:
    • The camshaft MUST be at the base circle position before the fuel pump is installed.
    • At the base circle position, the EN-51365  alignment gauge will sit flush with the cylinder head.
  3. Install the EN-51365  alignment gauge (2) and turn the crankshaft until the camshaft lobe is at the base circle position.
  4. Remove the EN-51365  alignment gauge (2) and valve lifter follower (1).
  5. GM4864734Courtesy of GENERAL MOTORS COMPANY

    Lubricate the NEW fuel pump housing seal (1) with clean engine oil and install it on the fuel pump. Adhesives, Fluids, Lubricants, and Sealers

  6. GM4864735Courtesy of GENERAL MOTORS COMPANY
    CAUTION:

    This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

    NOTE:
    • ALWAYS make sure the fuel pump bolt retainers are present before installing the fuel pump bolts.
    • If ANY fuel pump bolt retainers are missing or NOT suitable for reuse, replace the retainers as necessary.

    Install the NEW fuel pump bolts (1) through the fuel pump bolt retainers (2).

  7. GM4864736Courtesy of GENERAL MOTORS COMPANY

    Lubricate the valve lifter follower (1) again with clean engine oil, if necessary, and install it into the cylinder head bore. Adhesives, Fluids, Lubricants, and Sealers

  8. Install the fuel pump assembly (2) into the cylinder head and start the NEW fuel pump bolts (3) by hand.
    9. CAUTION:

    Refer to Fastener Caution .

    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.

  9. Tighten the NEW fuel pump bolts (3) to 25 N.m (18 lb ft).
  10. GM4864728Courtesy of GENERAL MOTORS COMPANY

    Install the fuel pump insulator (1).

  11. GM4864727Courtesy of GENERAL MOTORS COMPANY

    Position the engine wiring harness bracket (2).

  12. Install the engine wiring harness bracket bolts (1) and tighten to 25 N.m (18 lb ft).
  13. GM4864726Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Connect the engine wiring harness electrical connectors to the sensors that were previously disconnected.

    Position the engine wiring harness (3).

  14. Install the engine wiring harness clips (2) in the engine wiring harness bracket.
  15. Install the engine wiring harness ground bolt (1) and tighten to 10 N.m (89 lb in).
  16. GM4864722Courtesy of GENERAL MOTORS COMPANY

    Connect the electrical connector (1).

  17. GM4864721Courtesy of GENERAL MOTORS COMPANY

    Install the heater water auxiliary pump hose (2) to the water outlet.

  18. Use the BO-38185  pliers to engage the heater water auxiliary pump hose clamp (1).
  19. Install the heater water auxiliary pump hose (2) in the clip (3).
  20. Remove all EN-6015  plugs.
  21. GM4864720Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    High pressure fuel feed pipes are one time use only. ALWAYS install a NEW high pressure fuel feed pipe if the pipe is removed OR the fittings are loosened.

    Install the NEW fuel feed intermediate pipe (1). Fuel Feed Intermediate Pipe Replacement 

  22. GM4864719Courtesy of GENERAL MOTORS COMPANY

    Position fuel feed front pipe and bracket as necessary and connect the fuel feed front pipe (3) to the fuel pump. Fuel Feed Front Pipe Replacement 

  23. Position the fuel feed front pipe bracket (2) on the stud.
  24. Install the fuel feed front pipe bracket nut (1) and tighten to 9 N.m (80 lb in).
  25. GM4864718Courtesy of GENERAL MOTORS COMPANY

    Position the air cleaner resonator bracket (3).

  26. Install the air cleaner resonator bracket bolt (2) and tighten to 9 N.m (80 lb in).
  27. Install the engine wiring harness clip (1) to the bracket.
  28. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection
  29. Inspect for leaks using the following procedure:
    1. Turn ON the ignition with the engine OFF for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition with the engine OFF.
    4. Inspect for fuel leaks.
  30. Air Cleaner Outlet Duct - Install - Air Cleaner Outlet Duct Replacement 
  31. Intake Manifold Cover - Install - Intake Manifold Cover Replacement
  32. Air Inlet Grille Panel - Install - Air Inlet Grille Panel Replacement
  33. Fill the cooling system. Cooling System Draining and Filling
  34. Perform the fuel rail pressure relief valve learned values reset. Fuel Rail Pressure Relief Valve Learned Values Reset 
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