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Home >> Chevrolet >> 2022 >> Tahoe PPV, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 6 (Engine Controls And Fuel - 3.0L (Lm2) Diesel - Repair Instructions (2 Of 2)) >> Repair Instructions >> High Pressure Diesel Fuel Injection Rail Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
  1. GM5160608Courtesy of GENERAL MOTORS COMPANY

    Install the high pressure diesel fuel injection rail (1).

  2. GM5160483Courtesy of GENERAL MOTORS COMPANY
    CAUTION:

    Refer to Fastener Caution .

    Fuel Injection Fuel Rail Nut (1) - Install and tighten [3x] - Fastener Specifications

  3. GM5160480Courtesy of GENERAL MOTORS COMPANY

    Install and connect the glow plug wiring harness (1).

  4. GM5613883Courtesy of GENERAL MOTORS COMPANY

    Intake Air Pressure and Temperature Sensor (2) - Install

  5. Intake Air Pressure and Temperature Sensor Bolt (1) - Install and tighten - Fastener Specifications
  6. Connect the intake air pressure and temperature sensor electrical connector.
  7. GM5160453Courtesy of GENERAL MOTORS COMPANY

    Connect the high pressure diesel fuel sensor (1) and fuel pressure regulator (2) electrical connectors.

  8. GM5630549Courtesy of GENERAL MOTORS COMPANY

    Install NEW high pressure diesel fuel feed to injector pipe(s) (2).

  9. Hand tighten the high pressure diesel fuel feed to injector pipe fittings (1).
    10. CAUTION:

    Refer to Component Fastener Tightening Caution .

  10. Tighten the high pressure diesel fuel feed to injector pipe fittings (1). Fastener Specifications
  11. GM5158555Courtesy of GENERAL MOTORS COMPANY

    Install the fuel injection fuel feed pipe bracket (2).

  12. Install the fuel injection fuel feed pipe bracket bolt (1) and tighten. Fastener Specifications
  13. GM5628961Courtesy of GENERAL MOTORS COMPANY

    Install a NEW high pressure diesel fuel feed to rail pipe (2)

  14. Hand tighten the 2 high pressure diesel fuel feed to rail pipe fittings (1) to the high pressure diesel fuel injection rail.
  15. GM5810158Courtesy of GENERAL MOTORS COMPANY

    Fuel Injection Fuel Return Pipe (2) @ High Pressure Diesel Fuel Injection Rail - Connect

  16. Fuel Injection Fuel Return Pipe Retainer (1) - Install
  17. GM5156855Courtesy of GENERAL MOTORS COMPANY

    Install the 2 fuel feed pipe clip bolts (1) and tighten. Fastener Specifications

  18. Attach the fuel injector fuel return pipe retainer (2).
  19. GM5156840Courtesy of GENERAL MOTORS COMPANY

    Install the 2 fuel feed pipe clip bolts (1) and tighten. Fastener Specifications

  20. GM5156838Courtesy of GENERAL MOTORS COMPANY

    Hand tighten the 2 high pressure diesel fuel feed to rail pipe fittings (1) to the high pressure diesel fuel pump.

  21. Tighten the high pressure diesel fuel feed to rail pipe fittings to both the high pressure diesel fuel pump and the high pressure diesel fuel injection rail. Fastener Specifications
  22. GM5154342Courtesy of GENERAL MOTORS COMPANY

    Diesel Fuel Separator (1) - Install

  23. GM5154341Courtesy of GENERAL MOTORS COMPANY

    Diesel Fuel Separator Bracket Bolt (1) - Install and tighten - Fastener Specifications

  24. GM5153945Courtesy of GENERAL MOTORS COMPANY

    Fuel Pump Fuel Feed Hose (1) - Install

  25. GM5153904Courtesy of GENERAL MOTORS COMPANY

    Fuel Feed Pipe Clip Bolt (1) - Install and tighten - Fastener Specifications

  26. Front Wheelhouse Liner-Left Side - Install - Front Wheelhouse Liner Replacement
  27. GM5135087Courtesy of GENERAL MOTORS COMPANY
    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.

    Camshaft Housing Cover Insulator (1) - Install

  28. GM5149255Courtesy of GENERAL MOTORS COMPANY

    Exhaust Gas Recirculation Pipe Bracket (5) - Install

  29. Exhaust Gas Recirculation Pipe Bracket Bolt (1) - Install and tighten - Fastener Specifications
  30. Reposition harness, hoses, and connect electrical connectors as needed.
  31. GM5217574Courtesy of GENERAL MOTORS COMPANY

    Charge Air Cooler Bracket (2) - Install

  32. Charge Air Cooler Bolt (1) - Install and tighten [5x] - Fastener Specifications
  33. GM5499644Courtesy of GENERAL MOTORS COMPANY

    Engine Coolant Air Bleed Hose Clip (1) - Install

  34. GM5217555Courtesy of GENERAL MOTORS COMPANY

    Oil Filler Tube Support Stud (1) - Install and tighten - Fastener Specifications

  35. GM5499646Courtesy of GENERAL MOTORS COMPANY

    Engine Wiring Harness Bracket (3) - Install

  36. Engine Wiring Harness Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
  37. GM5138644Courtesy of GENERAL MOTORS COMPANY

    Turbocharger Bracket Bolt (1) - Install and tighten - Fastener Specifications

  38. GM5219691Courtesy of GENERAL MOTORS COMPANY

    Intake Manifold Resonator (2) - Install

  39. Engage the retaining spring (1).
  40. GM5185371Courtesy of GENERAL MOTORS COMPANY

    Turbocharger Heat Shield (1) - Install

  41. GM5185361Courtesy of GENERAL MOTORS COMPANY

    Turbocharger Heat Shield Nut (2) - Install and tighten - Fastener Specifications

  42. Turbocharger Heat Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
  43. GM5187895Courtesy of GENERAL MOTORS COMPANY

    Instal the upper intake manifold bracket (2) with the nitrogen oxides sensor.

  44. Upper Intake Manifold Brace Nut (1) - Install and tighten [3x] - Fastener Specifications
  45. GM5217156Courtesy of GENERAL MOTORS COMPANY

    Charge Air Cooler (1) - Install

  46. GM5217133Courtesy of GENERAL MOTORS COMPANY

    Charge Air Cooler Bolt (1) - Install and tighten [4x] - Fastener Specifications

  47. GM5211389Courtesy of GENERAL MOTORS COMPANY

    Charge Air Cooler Inlet Air Hose (2) - Install

  48. Charge Air Cooler Inlet Air Hose Clamp (1) - Tighten [2x] - Fastener Specifications
  49. GM5211335Courtesy of GENERAL MOTORS COMPANY

    Charge Air Cooler Outlet Air Hose (2) - Install

  50. Charge Air Cooler Outlet Air Hose Clamp (1) - Tighten [2x] - Fastener Specifications
  51. GM5216906Courtesy of GENERAL MOTORS COMPANY

    Connect the nitrogen oxides sensor electrical connector.

  52. Wiring Harness Retainer (4) @ Charge Air Cooler - Install
  53. GM5499648Courtesy of GENERAL MOTORS COMPANY

    Wiring Harness Retainer (2) @ Charge Air Cooler - Install [3x]

  54. Electrical Connector (1) @ Charge Air Cooler - Connect [2x]
  55. GM5628860Courtesy of GENERAL MOTORS COMPANY

    Install a NEW exhaust gas recirculation cooler inlet pipe gasket (3).

  56. Install a NEW exhaust gas recirculation pipe seal (2).
  57. Install the exhaust gas recirculation pipe (1).
  58. GM5208251Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

    Install and hand tighten the 2 exhaust gas recirculation pipe bolts (1).

  59. GM5204428Courtesy of GENERAL MOTORS COMPANY

    Exhaust Gas Recirculation Outlet Pipe Bolt (1) - Install and tighten [2x] - Fastener Specifications .

  60. GM5204427Courtesy of GENERAL MOTORS COMPANY

    Exhaust Gas Recirculation Outlet Pipe Bolt (2) - Install and tighten - Fastener Specifications

  61. Install the turbocharger coolant return hose clip (1).
  62. GM5206053Courtesy of GENERAL MOTORS COMPANY

    Install and tighten the turbocharger coolant feed and return pipe bolt (3). Fastener Specifications

  63. GM5204431Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

    Exhaust Gas Recirculation Cooler Bolt (1) - Install and tighten [2x] - Fastener Specifications .

  64. GM5193255Courtesy of GENERAL MOTORS COMPANY

    Engine Coolant Outlet Pipe Bracket Bolt (1) - Install and tighten - Fastener Specifications

  65. GM5170071Courtesy of GENERAL MOTORS COMPANY

    Install the rear engine wiring harness channel (2).

  66. Install the 3 engine wiring harness bracket nuts (1) and tighten. Fastener Specifications
  67. GM5150241Courtesy of GENERAL MOTORS COMPANY

    Air Cleaner Outlet Duct (2) - Install

  68. Air Cleaner Outlet Duct Clamp (1) - Tighten - Fastener Specifications
  69. GM5150211Courtesy of GENERAL MOTORS COMPANY

    Air Cleaner Outlet Front Duct Air Cleaner Outlet Duct Clamp (2) - Install

  70. Air Cleaner Outlet Duct Clamp (1) - Tighten [2x] - Fastener Specifications
  71. GM5171779Courtesy of GENERAL MOTORS COMPANY

    Oil Filler Cap - Remove

  72. Intake Manifold Cover (2) - Install
  73. Intake Manifold Cover Bolt (1) - Install and tighten - Fastener Specifications
  74. Oil Filler Cap - Install
  75. Plenum Front Panel Outer Reinforcement - Install - Plenum Front Panel Outer Reinforcement Removal and Installation
  76. Perform the high pressure fuel variable reset. High Pressure Fuel Variable Reset
  77. Prime the fuel system and inspect for leaks. Fuel System Priming
  78. Check for exhaust leak.
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