Installation Procedure
Fuel Injector Wiring Harness (1) - Install
Tie Strap (1) @ Direct Fuel Injection Fuel Rail - Install NEW [2x]
- Electrical Connector (4) @ Fuel Injection Fuel Rail Fuel Pressure Sensor - Connect
- Tie Strap (1) @ Fuel Injection Fuel Rail Fuel Pressure Sensor - Install NEW
- Electrical Connector (3) @ Knock Sensor - Connect [2x]
- Electrical Connector (2) @ Direct Fuel Injector - Connect [4x]
Connect the electrical connector. (1)
- 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
Engine Coolant Flow Control Valve Seal (2) - Install NEW
- Engine Coolant Flow Control Valve (1) - Install
- CAUTION:
Refer to Fastener Caution .
Engine Coolant Flow Control Valve Bolt (1) - Install and tighten [5x] - Fastener Specifications
Electrical Connector (1) @ Engine Coolant Flow Control Valve - Connect [3x]
Engine Coolant Thermostat Housing Inlet Pipe (2) @ Engine Coolant Flow Control Valve - Install
- Thermostat Bypass Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Thermostat Bypass Hose (2) @ Exhaust Manifold Outlet Pipe - Install
- Thermostat Bypass Hose Clamp (1) @ Exhaust Manifold Outlet Pipe - Engage - Hose Clamp Replacement Guidelines - Spring Type
Engine Coolant Thermostat Housing Bracket Bolt (1) - Install and tighten - Fastener Specifications
Exhaust Manifold Outlet Pipe Bolt (2) - Install and tighten - Fastener Specifications
Engine Oil Cooler Coolant Inlet Hose (2) @ Engine Coolant Flow Control Valve - Install
- Engine Oil Cooler Coolant Inlet Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Thermostat Bypass Pipe (2) @ Engine Coolant Flow Control Valve - Install
- Thermostat Bypass Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
- NOTE:
Some components not shown for graphic clarity.
Thermostat Bypass Pipe Bolt (1) - Install and tighten - Fastener Specifications
Radiator Inlet Hose (2) @ Engine Coolant Flow Control Valve - Install
- Radiator Inlet Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
- Install underbody panels as necessary. Underbody Panel Component Locator
Intake Manifold Gasket (1) - Install NEW [4x]
Crankcase Vent Passage Seal (1) - Install NEW
Intake Manifold (2) - Install
- Intake Manifold Bolt (1) - Install and hand tighten [6x]
- Intake Manifold Bolt (1) - Tighten in sequence [6x] - Fastener Specifications
Intake Manifold Cover (1) - Install
Intake Manifold Cover Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Reposition the wiring harness.
- Connect the electrical connectors and install the wiring harness retainers as necessary.
Evaporative Emission Canister Purge Pump (2) - Install
- Evaporative Emission Canister Purge Pump Bolt (1) - Install and tighten [3x] - Fastener Specifications
- Connect the electrical connector.
Evaporative Emission Canister Purge Tube (1) - Connect - Plastic Collar Quick Connect Fitting Service
Evaporative Emission Front Pipe (1) - Connect - Plastic Collar Quick Connect Fitting Service
Fuel Feed Pipe Bolt (1) - Install and tighten - Fastener Specifications
Transmission Vent Hose Clip (3) @ Fuel Feed Front Pipe Bracket (2) - Engage
- Fuel Feed and Evaporative Emission Canister Vent Pipe Clip (1) @ Fuel Feed Front Pipe Bracket (2) - Engage
Oil Level Indicator Tube Bracket Bolt (1) - Install and tighten - Fastener Specifications
Oil Level Indicator (1) - Install
- CAUTION:
Verify the charge air cooler inlet and outlet air tube quick connect seal condition and location prior to installation. Seal must be evenly seated in the quick connector body and sealing surface must be free of deformation and damage. Deformed or damaged seals can lead to reduced engine power and/or engine stalling.
NOTE:DO NOT insert fingers inside quick connect to manipulate duct during disassembly/assembly. Rubber pad gloves increase risk to dislodge seal.
Charge Air Cooler Outlet Air Hose (2) - Install
- Engage the charge air cooler outlet air hose retainer spring (1).
Air Cleaner Outlet Duct (1) - Install
Air Cleaner Outlet Duct Clamp (2) - Tighten - Fastener Specifications
- Evaporative Emission Canister Purge Tube (1) - Connect - Plastic Collar Quick Connect Fitting Service
- Connect the electrical connector.
Air Cleaner Outlet Duct Clamp (3) - Tighten - Fastener Specifications
- Positive Crankcase Ventilation Tube (2) - Connect - Plastic Collar Quick Connect Fitting Service
- Air Cleaner Outlet Duct Nut (1) - Install and tighten [2x] - Fastener Specifications
{If equipped} Intake Manifold Cover (1) @ Upper Intake Manifold Bracket (2) - Install
If equipped, push down on the front of the intake manifold cover (2).
- {If equipped} Intake Manifold Cover Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Connect the battery negative cable. Battery Negative Cable Disconnection and Connection
- Fill the cooling system. Cooling System Draining and Filling (GE 47716) , or Cooling System Draining and Filling (Static)