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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 430 (Engine Controls - Removal & Installation - Bi-Fuel & CNG) >> Relays, Motors & Solenoids >> High Pressure Lock-Off Solenoid >> Installation

High Pressure Lock-Off Solenoid: Installation

WARNING: This page is about a different car, the 2003 GMC Savana and 2003 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install a NEW "O" ring on the HPL solenoid. Lubricate "O" ring with petroleum jelly or equivalent before installation. Install the HPL solenoid in the tank and tighten hand-tight. Install the tank into the vehicle ensuring that the HPL solenoid will be properly oriented for reconnection of the fuel lines. Install the tank using the OLD mounting strap nuts and bolts. DO NOT install the fuel line fittings.
  2. Tighten the HPL solenoid. See TORQUE SPECIFICATIONS . See TORQUE ADAPTOR COMPENSATION  under TORQUE SPECIFICATIONS. Remove the OLD mounting strap nuts and bolts and discard them. Ensure that the tank is properly oriented for fuel line connection.
  3. Install NEW mounting strap bolts and nuts. Tighten the mounting strap nuts. Complete the fuel tank installation by connecting the fuel lines, electrical connectors and fuel tank pressure sensor. See FUEL TANKS  under FUEL SYSTEMS.
    4. WARNING: The high pressure lock-off solenoid seal is more likely to leak at a lower fuel pressure. Always perform the fuel leak procedure exactly as specified. Failure to follow the proper procedures may result in serious injury or damage to the vehicle or part.
  4. Fuel the vehicle and check for CNG fuel leaks in 3 stages at the following pressures: 500 psi 1,500 psi and 3,000 psi. Using Ultrasonic Leak Detector (J 45878), inspect for fuel leaks at the HPL solenoid at each pressure. Connect the negative battery cable. Start and operate the engine on CNG. Inspect for fuel leaks at each serviced fitting using ultrasonic leak detector. Attach the information label supplied with the replacement HPL solenoid in a visible location on the head of the tank. Install the tank shield. See FUEL TANK SHIELD  under FUEL SYSTEMS.
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