Installation Procedure
Lubricate the fuel injector seals (2) with a drop of clean engine oil. Adhesives, Fluids, Lubricants, and Sealers
Holding the largest diameter / body (2) of the injector only, insert the injector assembly (2) into the fuel rail. Ensure correct orientation of the electrical connector.
- Fuel Injector Retainer (1) - Install NEW
- Connect the electrical connectors and install the wiring harness retainers as necessary.
- NOTE:
DO NOT use any type of lubricant when installing the NEW combustion 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.
- NOTE:
The fuel injector nozzle housing seals must fit properly in the relative groove. Overlapping of the fuel injector nozzle housing seals with the external surface of the injector must be avoided.
Check both of the fuel injector nozzle housing seals on each fuel injector for correct seat:
- The fuel injector nozzle housing seal must not be too large, buckled, or corrugated (1)
- The fuel injector nozzle housing seal must be fixed tight and accurate (2)
- If the fuel injector nozzle housing seals are not installed correctly, remove the incorrect fuel injector nozzle housing seal and replace with a NEW fuel injector nozzle housing seal.
- NOTE:
Start the direct fuel injection fuel rail bolts by hand then draw the direct fuel injection fuel down evenly prior to tightening.
Install the direct fuel injection fuel rail (2) to the cylinder head.
- Fuel Injection Fuel Rail Bolt (1) @ Direct Fuel Injection Fuel Rail (2) - Install and tighten [4x] - Fastener Specifications
Connect the electrical connectors and install the wiring harness retainers as necessary. (2, 3)
- 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
Intake Manifold Gasket @ Intake Manifold (1) - Install NEW
Intake Manifold (2) - Install
- Intake Manifold Bolt (1) - Install and hand tighten [5x]
- Intake Manifold Bolt (1) - Tighten in sequence [5x] - Fastener Specifications
Intake Manifold Cover (1) - Install
- Connect the electrical connectors and install the wiring harness retainers as necessary.
- Oil Level Indicator - Install
Oil Level Indicator Tube Bracket Bolt (2) - Install and tighten - Fastener Specifications
- Intake Manifold Cover Bolt (1) - Install and tighten [3x] - Fastener Specifications
Install the hose retainers (1) as necessary.
Install the hose retainers (1) as necessary.
Charge Air Cooler Coolant Hose (2) - Install
- Charge Air Cooler Inlet Air Hose Clamp Nut (1) - Install and tighten - Fastener Specifications
Charge Air Cooler Bracket (1) - Install
Charge Air Cooler Bracket Bolt (1) - Install and tighten [4x] - Fastener Specifications
Fuel Feed Intermediate Pipe (2) - Install NEW
- Fuel Feed Intermediate Pipe Nut (1) @ Fuel Feed Intermediate Pipe - Tighten [2x] - Fastener Specifications
- Fuel Injection Fuel Feed Pipe Bracket Bolt (1) - Install and tighten - Fastener Specifications
- Retainer (3) - Engage
Radiator Surge Tank Air Separator Hose Bracket (2) - Install
- Radiator Surge Tank Outlet Pipe Nut (1) - Install and tighten - Fastener Specifications
- 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 Pump Insulator (1) - Install
Charge Air Cooler (1) - Install
Charge Air Cooler Coolant Hose Clamp (4) - Tighten - Fastener Specifications
- Charge Air Cooler Coolant Hose (3) - Install [2x]
- Charge Air Cooler Coolant Hose Retainer (2) - Engage [2x]
- Charge Air Cooler Outlet Air Hose Clamp (1) - Tighten - Fastener Specifications
- Connect the electrical connector. (5)
Charge Air Cooler Bolt (1) - Install and tighten [4x] - Fastener Specifications
Air Cleaner Outlet Duct (4) - Install
- Air Cleaner Outlet Duct Nut (3) - Install and tighten - Fastener Specifications
- Air Cleaner Outlet Duct Bolt (2) - Install and tighten [2x] - Fastener Specifications
- Air Cleaner Outlet Duct Clamp (5) - Tighten - Fastener Specifications
- Turbocharger Outlet Duct Front Clamp (1) - Tighten - Fastener Specifications
Positive Crankcase Ventilation Fresh Air Tube (1) @ Air Cleaner Outlet Duct - Connect - Plastic Collar Quick Connect Fitting Service
Oil Filler Cap (1) - Remove
Intake Manifold Cover (1) - Install
Oil Filler Cap - Install
- Connect the battery negative cable. Battery Negative Cable Disconnection and Connection
- Fill the cooling system to the proper level. Cooling System Draining and Filling (GE 47716)
- Inspect for fuel leaks using the following procedure:
- 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.
Refer to Fastener Caution .