Installation Procedure
- CAUTION:
Refer to Component Fastener Tightening Caution .
Fuel Rail Pressure Sensor (1) - Install and tighten - Fastener Specifications
Fuel Injection Fuel Rail Seal (3) - Install NEW
- Install the fuel injector (2) to the fuel rail.
- Install NEW fuel injector retainer (1) to the fuel injector (2).
- NOTE:
Do not use any type of lubricant when installing the NEW seals (2) on the fuel injector tip.
Install EN 49245-1 long protector (3) onto the fuel injector tip, covering the first recessed area closest to the tip. Place a NEW seal (2) on EN-49245-1 long protector.
- Using EN-49245-3 pusher (1), install the seal into the second recessed area (4) of the fuel injector.
- Compress the seal with your fingers, then resize the seal using the EN-49245-4 sizer (5).
- Inspect the NEW fuel injector nozzle housing seals on ALL injectors, ensuring the seals are seated correctly. All seals must be fixed tight, and accurately to the fuel injector nozzle, with no overlap, buckling, or corrugation present. Replace any seal that is incorrectly seated on the fuel injector nozzle with a NEW seal.
- NOTE:
Do not use any type of lubricant when installing the NEW seals (2) on the fuel injector tip.
Install EN-49245-2 short protector (3) onto the fuel injector tip. Place a NEW seal (2) on EN-49245-2 short protector.
- Using EN-49245-3 pusher (1), install the seal into the first recessed area (4) of the fuel injector.
- Compress the seal with your fingers, then resize the seal using the EN-49245-4 sizer (5).
Fuel Injection Fuel Rail Wiring Harness (4) - Install
- Connect the 4 fuel injection fuel rail electrical connectors (3).
- Wiring Harness Retainer (2) - Engage [2x]
- Install NEW tie strap (1)
- NOTE:
The fuel injection fuel rail bolts are retained into the rails using keepers. Care should be taken to ensure that the threadlock is installed after the fasteners are installed in their bore.
If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Remove loose debris from internal and external threads using compressed air.
- Apply liquid thread locking adhesive in a strip along half of the length of the external threads, starting at the tip, just prior to installation. Adhesives, Fluids, Lubricants, and Sealers
- Fuel Injection Fuel Rail Bolt (1) - Install and tighten [4x] - Fastener Specifications
- NOTE:
The fuel injection fuel rail bolts are retained into the rails using keepers. Care should be taken to ensure that the threadlock is installed after the fasteners are installed in their bore.
If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Remove loose debris from internal and external threads using compressed air.
- Apply liquid thread locking adhesive in a strip along half of the length of the external threads, starting at the tip, just prior to installation. Adhesives, Fluids, Lubricants, and Sealers
- Fuel Injection Fuel Rail Bolt (1) - Install [4x]
- Install the fuel injection fuel rail assembly (2) to the cylinder head.
- Fuel Injection Fuel Rail Bolt (1) - Tighten [4x] - Fastener Specifications
- Connect the electrical wiring harness connectors to the fuel rail as needed.
- NOTE:
Do NOT reuse the fuel feed intermediate pipe. If the fuel feed intermediate pipe fittings are loosened or the pipes are removed, the pipes MUST be replaced.
Fuel Feed Intermediate Pipe (1) - Install NEW
- Slide fuel feed pipe fitting nuts (2) back along fuel feed intermediate pipe (1) to reveal the formed ends (3) of the fuel feed pipe.
- Carefully install the formed ends (3) of the fuel feed intermediate pipe into the sockets of the fuel pump (4) and the fuel injection fuel rails (5).
- Hold the pipe firmly in place and hand tighten the fuel feed pipe fitting nuts (2) onto the threads on the fuel injection fuel rails (5) and the fuel pump (4).
- Fuel Feed Intermediate Pipe Nut (2) @ Fuel Feed Intermediate Pipe (1) - Tighten [3x] - Fastener Specifications
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling 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.
Engine Rear Noise Shield (1) - Install
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling 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
Lower Intake Manifold Gasket (2) - Install NEW [6x]
- Intake Manifold (1) - Install
If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps:
- Remove any loose cured adhesive from the external threads of the component using a lint free cloth.
- Thread the cleaned component into the internal mating threads and remove to loosen trapped cured adhesive.
- Remove loose debris from internal and external threads using compressed air.
- Apply liquid thread locking adhesive in a strip along half of the length of the external threads, starting at the tip, just prior to installation. Adhesives, Fluids, Lubricants, and Sealers
- Lower Intake Manifold Bolt (1) - Install and hand tighten [6x]
- Lower Intake Manifold Bolt (1) - Tighten in sequence [6x] - Fastener Specifications
- Connect all electrical connectors.
- NOTE:
Some components not shown for graphic clarity.
Positive Crankcase Ventilation Foul Air Tube (2) - Install
- Positive Crankcase Ventilation Tube Connector (1) - Connect [2x] - Plastic Collar Quick Connect Fitting Service
Fuel Pipe Shield (1) - Install
Wiring Harness (3) - Install
- Retainer (2) - Install [3x]
- Engine Rear Noise Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
Install the plenum front panel (3) to the dash panel upper insulator (2).
- Plenum Panel Nut (1) - Install [9x]
Plenum Front Panel (1) - Install
Plenum Front Panel Bolt (1) - Install and tighten [4x] - Fastener Specifications
- Plenum Front Panel Nut (2) - Install and tighten [3x]
Plenum Front Panel Nut (1) - Install and tighten [3x] - Fastener Specifications
- Plenum Front Panel Bolt (2) - Install and tighten [3x] - Fastener Specifications
- Install the forward lamp wiring harness extension (3) into the plenum front panel.
- Connect the electrical connector.
Air Inlet Deflector Water Deflector (1) - Install
Air Inlet Deflector Water Deflector Retainer (1) - Install [2x]
Install the windshield wiper system module (2) in the vehicle.
- Windshield Wiper System Module Bolt (1) - Install and tighten [2x] Fastener Specifications
- Connect the windshield wiper motor electrical connector.
- Connect the battery negative cable. - Battery Negative Cable Disconnection and Connection
Windshield Wiper System Module Shield (1) - Install
Air Inlet Grille Panel (2) - Install
- Install the air inlet grille panel (2) between both hood hinges.
- Connect the windshield washer nozzle hose to the windshield washer pump hose.
- Air Inlet Grille Panel Retainer (1) - Install [6x]
Front Compartment Side Sight Shield (2) - Install
- Front Compartment Side Sight Shield Retainer (1) - Install [3x]
Air Inlet Grille Panel Extension (2) - Install
- Air Inlet Grille Panel Retainer (1) - Install [2x]
Install the hood rear outer air inlet seal (2) to the left and right side.
- Install the 2 hood rear outer air inlet seal retainer (1) to the left and right side.
Air Inlet Grille Panel Extension (1) - Install [2x]
- Install the air inlet grille panel extension (1).
- Remove the masking tape from the top edge of the service part.
- Using a 50/50 mixture of isopropyl alcohol and clean drinkable water with a clean towel, remove any left over adhesive residue from the masking tape.
Windshield Wiper Arm (3) - Install [2x]
- Clean the windshield wiper transmission pivot shaft splines with a soft wire brush before installing the windshield wiper arm (3).
- Position the windshield wiper arm (3) on the windshield wiper transmission pivot shaft.
- Windshield Wiper Arm Nut (2) - Install and tighten Fastener Specifications
- Windshield Wiper Arm Finish Cap (1) - Install
If required, realign the windshield wipers to their respective alignment circles (1) on the windshield.
- Lubricate the windshield with clean washer fluid.
- Run the windshield wipers for two complete cycles then turn off the windshield wipers.
- Ensure the windshield wipers are in the full park position.
- Inspect the windshield wipers for proper position to the alignment circles (1) on the windshield.
- Pressurize the fuel system and inspect for leaks.
Engine Rear Noise Shield Bolt (1) - Install and tighten - Fastener Specifications
- NOTE:
Some components not shown for graphic clarity.
Charge Air Cooler Cover Seal (3) - Install NEW [2x]
- Intake Manifold Gasket (2) - Install NEW
- Charge Air Cooler Cover (1) - Install
- NOTE:
Some components not shown for graphic clarity.
Charge Air Cooler Cover Bolt (2) - Install and hand tighten [12x]
- Charge Air Cooler Cover Bolt (2) - Tighten in sequence [12x] - Fastener Specifications
- Charge Air Cooler Bolt (1) - Install and hand tighten [2x]
- Charge Air Cooler Bolt (1) - Tighten in sequence [2x] - Fastener Specifications
- Connect the electrical connector.
Charge Air Cooler Inlet Air Tube Seal (4) - Install NEW
- Charge Air Cooler Inlet Pipe (3) - Install
- Charge Air Bypass Valve Tube Connector Clamp (2) - Tighten - Fastener Specifications
- Charge Air Cooler Inlet Air Tube Bolt (1) - Install and tighten [2x] - Fastener Specifications
Charge Air Bypass Valve (3) - Install
- Charge Air Bypass Valve Tube Connector Clamp (2) - Tighten - Fastener Specifications
- Charge Air Bypass Valve Hose Clamp (1) - Tighten - Fastener Specifications
Charge Air Cooler Inlet Air Tube Seal (4) - Install NEW
- Charge Air Cooler Inlet Pipe (3) - Install
- Charge Air Bypass Valve Tube Connector Clamp (2) - Tighten - Fastener Specifications
- Charge Air Cooler Inlet Air Tube Bolt (1) - Install and tighten [2x] - Fastener Specifications
Charge Air Bypass Valve (3) - Install
- Charge Air Bypass Valve Tube Connector Clamp (2) - Tighten - Fastener Specifications
- Charge Air Bypass Valve Hose Clamp (1) - Tighten - Fastener Specifications
Charge Air Cooler Coolant Pipe Seal (3) - Install NEW [4x]
- Supercharger Water Manifold Gasket (2) - Install NEW [2x]
- Supercharger Water Manifold (1) - Install
Charge Air Cooler Coolant Manifold Bolt (1) - Install and tighten [4x] - Fastener Specifications
Charge Air Cooler Coolant Hose (4) - Install
- Charge Air Cooler Coolant Hose Clamp (3) - Engage - Hose Clamp Replacement Guidelines - Spring Type
- Charge Air Cooler Coolant Hose (2) - Install
- Charge Air Cooler Coolant Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Turbocharger Wastegate Actuator Vacuum Tank (2) - Install
- Turbocharger Wastegate Actuator Vacuum Tank Bolt (1) - Install and tighten [2x] - Fastener Specifications
Electrical Connector (1) @ Charge Air Bypass Valve (2) - Connect
Charge Air Bypass Valve Tube (1) @ Charge Air Bypass Valve - Connect - Plastic Collar Quick Connect Fitting Service
Electrical Connector (1) @ Charge Air Bypass Valve (2) - Connect
Charge Air Bypass Valve Tube (1) @ Charge Air Bypass Valve - Connect - Plastic Collar Quick Connect Fitting Service
Turbocharger Wastegate Actuator Vacuum Source Tube @ Vacuum Pump - Connect - Plastic Collar Quick Connect Fitting Service
Charge Air Bypass Valve Vacuum Tank Tube (3) - Connect - Plastic Collar Quick Connect Fitting Service
Turbocharger Wastegate Actuator Vacuum Tank Solenoid Valve Tube (3) @ Auxiliary Air Cleaner Outlet Duct - Connect - Plastic Collar Quick Connect Fitting Service
Turbocharger Wastegate Actuator Vacuum Tank Bolt (3) - Install and tighten [2x] - Fastener Specifications
- Connect the turbocharger wastegate regulator solenoid valve electrical connector.
Turbocharger Wastegate Actuator Vacuum Tank Bolt (3) - Install and tighten [2x] - Fastener Specifications
- Connect the turbocharger wastegate regulator solenoid valve electrical connector.
Evaporative Emission Canister Purge Tube (1) - Install
- Evaporative Emission Canister Purge Tube (1) - Connect [2x] - Plastic Collar Quick Connect Fitting Service
Oil Filler Cap - Remove
- Intake Manifold Cover (2) - Install
- Intake Manifold Cover Bolt (1) - Install and tighten - Fastener Specifications
- Oil Filler Cap - Install
- Fill the charge air cooling system. Cooling System Draining and Filling (LSY GE 47716) , or Cooling System Draining and Filling (LSY Static Fill) , or Cooling System Draining and Filling (LSY with V03 Static Fill) , or Cooling System Draining and Filling (L3B Static Fill) , or Cooling System Draining and Filling (L3B GE 47716) , or Cooling System Draining and Filling (LSY with V03 GE 47716) , or Cooling System Draining and Filling (LF4 Static Fill) , or Cooling System Draining and Filling (LF4 GE 47716)
The EN-49245-4 sizer is two sided, and either direction will size the seal correctly.
The EN-49245-4 sizer is two sided, and either direction will size the seal correctly.
Start the fuel injection fuel rail bolts by hand then draw the injector rail down evenly prior to tightening.
Refer to Fastener Caution .
Start the fuel injection fuel rail bolts by hand then draw the injector rail down evenly prior to tightening.
This is a push nut.