Installation Procedure
- NOTE:
Do NOT use any type of lubricant when installing the NEW combustion fuel injector seal on the fuel injector tip.
Install the EN-51955-2 short protector (4) onto the fuel injector tip. Place a NEW combustion fuel injector seal (2) on the EN-51955-2 short protector (4).
- Using the EN-51955-4 pusher (3), install the combustion fuel injector seal (2) into the recessed area (1) of the fuel injector, then remove the EN-51955-2 short protector.
Compress the combustion fuel injector seal (1) using the EN-51955-3 pre-sizer (2).
Using the EN-51955-5 Fuel Injector Seal Sizer (2), resize the combustion fuel injector seal (1).
- Install a combustion fuel injector seal on each of the remaining direct fuel injectors using the same procedure.
- NOTE:
Check that the gaps of the two fuel injector seal retainers are aligned.
Fuel Injector Seal Retainer - Red (3) - Install [3x]
- Fuel Injector Seal Retainer - White (2) - Install [3x]
- Fuel Injector Seal (1) - Install NEW [3x]
- NOTE:
- Lubricate the fuel injector seal with engine oil.
- Note the orientation of the fuel injector retainers when installed.
Direct Fuel Injector (3) @ Direct Fuel Injection Fuel Rail (1) - Install [3x]
- Connect the electrical connector. (4) [3x]
- Fuel Injector Retainer (2) - Install NEW [3x]
Direct Fuel Injection Fuel Rail (2) - Install
- Fuel Injection Fuel Rail Bolt (1) - Loosely install [4x]
- NOTE:
Tighten only the 2 fuel injection fuel rail bolts shown until the direct fuel injection fuel rail is seated to the cylinder head.
Tighten the fuel injection fuel rail bolt (1) by hand 1/2 turn.
- Tighten the fuel injection fuel rail bolt (2) by hand 1/2 turn.
- Continue to tighten these two bolts by hand in 1/2 turn increments until the direct fuel injection fuel rail is seated to the cylinder head.
- CAUTION:
Fuel Injection Fuel Rail Bolt (1) - Tighten in sequence [4x] - Fastener Specifications
Electrical Connector (1) - Connect
Fuel Feed Intermediate Pipe (3) - Install NEW
- Fuel Feed Intermediate Pipe Nut (2) - Loosely install [2x]
- Fuel Feed Intermediate Pipe Bolt (2) - Install and tighten - Fastener Specifications
- Fuel Feed Intermediate Pipe Nut (1) - Tighten - Fastener Specifications
Fuel Pump Cover (2) - Install
- Fuel Pump Shield Bolt (1) - Install and tighten [3x] - Fastener Specifications
Ground Cable (2) - Install
- Stud (1) - Install and tighten to 9 N.m (80 lb in)
Retainer (1) - Connect [5x]
Turbocharger Wastegate Regulator Solenoid Valve (1) - Install
- Turbocharger Wastegate Regulator Solenoid Valve Bolt (1) - Install and tighten [2x] - Fastener Specifications
Camshaft Cover Gasket (3) - Install NEW
- Camshaft Cover (1) - Install
Camshaft Cover Bolt (1) - Install and hand tighten [17x]
- Camshaft Cover Bolt (1) - Tighten in sequence [17x] - Fastener Specifications
Oil Level Indicator - Install
Inspect the inside of the ignition coil boot for a thin, even coat of dielectric grease. If there is no grease present or additional grease is necessary, apply a thin coating of dielectric grease to the inside of the ignition coil boot up to a depth of 15 mm (0.60 in) from the end of the boot. Adhesives, Fluids, Lubricants, and Sealers
- Remove any excess dielectric grease from around the end of the ignition coil boot and ensure there is not an excessive amount within the boot.
- Ignition Coil (2) - Install [3x]
- Ignition Coil Bolt (1) - Install and tighten [6x] - Fastener Specifications
Ignition Coil Connector (6) - Connect [3x]
- Retainer (5) - Connect [6x]
- Turbocharger Coolant Return Pipe Bracket (1, 4) - Install
- Turbocharger Coolant Return Pipe Bracket Bolt (2, 3) - Install and tighten [2x] - Fastener Specifications
Positive Crankcase Ventilation Vacuum Hose (2) - Install
- Positive Crankcase Ventilation Vacuum Hose Clamp @ Camshaft Cover (1) - Engage
Positive Crankcase Ventilation Vacuum Hose (1) - Install
Positive Crankcase Ventilation Vacuum Hose Clamp (2) - Engage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Connect the electrical connector. (1)
Evaporative Emission Canister Purge Tube (1) - Install
Evaporative Emission Canister Purge Tube (1) @ Evaporative Emission Canister Purge Pump (2) - Connect - Plastic Collar Quick Connect Fitting Service
Evaporative Emission Canister Purge Tube (1) @ Evaporative Emission Canister Purge Solenoid Valve (2) - Connect - Plastic Collar Quick Connect Fitting Service
Evaporative Emission Canister Purge Tube Clip (1) - Install [3x]
Engine Wiring Harness (2) - Install
- Wiring Harness Retainer (1) - Secure [2x]
Evaporative Emission Pipe-Underbody (1) - Install
- Evaporative Emission Pipe-Underbody (1) @ Retainer (2) - Install [3x]
Evaporative Emission Pipe-Underbody (1) @ Evaporative Emission Canister Purge Pump (2) - Connect - Plastic Collar Quick Connect Fitting Service
Fuel Feed Front Pipe (1) @ Vehicle - Install
Fuel Feed Front Pipe (1) @ Fuel Feed Pipe - Underbody (2) - Connect - Metal Collar Quick Connect Fitting Service
Fuel Feed Front Pipe (1) @ Fuel Pump (2) - Connect - Metal Collar Quick Connect Fitting Service
Charge Air Cooler Inlet Air Hose @ Turbocharger Assembly - Install
- Charge Air Cooler Inlet Air Hose Retainer Spring (1) - Engage
Charge Air Cooler Inlet Air Hose Clamp Nut (1) - Install and tighten - Fastener Specifications
Clip (2) - Install [2x]
- Wiring Harness Retainer (1) - Install [3x]
Air Cleaner Assembly (1) - Install
Air Cleaner Outlet Front Duct (2) @ Air Cleaner Assembly (3) - Install
- Air Cleaner Clamp (1) - Tighten - Fastener Specifications
Wiring Harness Retainer (2) - Install
- Electrical Connector (1) - Connect
Turbocharger Wastegate Actuator Vacuum Control Solenoid Valve Filter Hose (1) @ Air Cleaner Assembly (2) - Install
Intake Air Duct (1) - Install
Intake Air Duct Retainer (1) - Install [2x]
Air Cleaner Outlet Front Duct (1) - Install
Air Cleaner Outlet Duct Clamp (2) - Tighten - Fastener Specifications
- Air Cleaner Clamp (1) - Tighten - Fastener Specifications
Intake Manifold Cover (3) - Install
- Oil Filler Cap Seal (2) - Install
- Oil Filler Cap (1) - Install
- Connect the battery negative cable. Battery Negative Cable Disconnection and Connection
- 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.
Check that the locating pins (2, 4) sits correct in their hole.
Make sure that the camshaft cover heat shield is not trapped between the camshaft cover and the cylinder head. Otherwise, the heat shield could be damaged.