Installation Procedure
Wiring Harness Connector Seal (1) @ Valve Rocker Arm Oil Control Valve Harness (2) - Install NEW
- NOTE:
Ensure proper use of room temperature vulcanizing (RTV) sealant.
Apply sealant to the drive motor oil filler hole plug (1). Adhesives, Fluids, Lubricants, and Sealers
- Install and tighten the drive motor oil filler hole plug (1) to the engine block valley cover (2). Fastener Specifications
- NOTE:
All gasket surfaces should be free of oil or other foreign material during assembly.
Engine Block Valley Cover Gasket (2) @ Engine Block Valley Cover (1) - Install NEW
Engine Block Valley Cover (1) - Install
- Engine Block Valley Cover Bolt (2) Hand tighten - [ 9x ]
- Engine Block Valley Cover Bolt (2) Tighten in sequence - [ 9x ] - Fastener Specifications
Valve Rocker Arm Oil Control Valve Extension Harness (1) @ Valve Rocker Arm Oil Control Valve Harness - Connect
- NOTE:
Do NOT use any type of lubricant when installing the NEW 4 bank 1 fuel injector seals (1) on the fuel injector.
Fuel Injector Seal (1) - Install NEW [ 4x ]
- NOTE:
Do NOT use any type of lubricant when installing NEW seals (2) on the injector.
Install EN-51105-1 Seal Installer Long Guide (3) onto the fuel injector tip. Place a NEW seal (2) on EN-51105-1 Seal Installer Long Guide.
- Using EN-49245-3 Seal Installer Pusher (1), install the seal onto the first recessed area (4) of the fuel injector.
- Compress the seal with your fingers, then resize the seal using the EN-49245-4 Seal Sizer (5).
NOTE:The EN-49245-4 Seal Sizer is two sided, and either direction will size the seal correctly.
- NOTE:
Do NOT use any type of lubricant when installing NEW seals (2) on the injector.
Install EN-51105-2 Seal Installer Short Guide (3) onto the fuel injector tip. Place a NEW seal (2) on EN-51105-2 Seal Installer Short Guide.
- Using EN-49245-3 Seal Installer Pusher (1), install the seal onto the second recessed area (4) of the fuel injector.
- Compress the seal with your fingers, then resize the seal using the EN-49245-4 Seal 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:The EN-49245-4 Seal Sizer is two sided, and either direction will size the seal correctly.
- 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.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Fuel Injection Fuel Rail Bolt (1) @ Fuel Injection Fuel Rail (2) - Install [ 4x ]
- Install the fuel injection fuel rail assembly (2) to the cylinder head.
- Fuel Injection Fuel Rail Bolt (1) - Tighten [ 4x ] - Fastener Specifications
- NOTE:
The camshaft must be in the base circle position before the fuel pump is installed.
Using the EN-51092 Fuel Pump Installation Gauge (2) ensure that the camshaft lobe is in the base circle position. At base circle position, the EN-51092 Fuel Pump Installation Gauge (2) will be flush with the top surface of the lifter oil manifold assembly (1).
Ensure the 2 plastic fastener retainers (3) are installed in the fuel pump mounting holes before installing the fuel pump.
- Fuel Pump Bracket Gasket (5) - Install NEW
- Fuel Pump (4) - Install
- Fuel Pump Cover (2) - Install
- Fuel Pump Bolt (1) - Install and hand tighten [ 2x ]
- Fuel Pump Bolt (1) - Tighten [ 2x ] - Fastener Specifications
- Reposition the fuel pump and fuel injector wiring harness and connect as necessary.
- NOTE:
Do NOT reuse the fuel feed intermediate pipe (1). If the 2 fuel feed intermediate pipe nuts (3) are loosened or the fuel feed intermediate pipes are removed, the fuel feed intermediate pipes MUST be replaced.
Fuel Feed Intermediate Pipe (1) - Install NEW
- Slide the 2 fuel feed intermediate pipe nuts (3) back along fuel feed intermediate pipe (1) to reveal the 2 formed ends (2) of the fuel feed intermediate pipe (1).
- Carefully install the 2 formed ends (2) of the fuel feed intermediate pipe (1) into the sockets of the left and right fuel injection fuel rail. Take care not to hit the 2 formed ends (2) of the fuel feed intermediate pipe (1) on the threaded sockets on the fuel injection fuel rails.
- Hold the fuel feed intermediate pipe (1) firmly in place and hand tighten the 2 fuel feed intermediate pipe nuts (3).
- Fuel Feed Pipe Bolt (4) - Tighten - Fastener Specifications
- Fuel Feed Intermediate Pipe Nut (3) - Tighten [ 2x ] - Fastener Specifications
- NOTE:
Do NOT reuse the fuel feed intermediate pipe (1). If the 2 fuel feed intermediate pipe nuts (2) are loosened or the fuel feed intermediate pipes are removed, the fuel feed intermediate pipes MUST be replaced.
Fuel Feed Intermediate Pipe (1) - Install NEW
- Slide the 2 fuel feed intermediate pipe nuts (2) back along fuel feed intermediate pipe (1) to reveal the 2 formed ends (3) of the fuel feed intermediate pipe (1).
- Carefully install the 2 formed ends (3) of the fuel feed intermediate pipe (1) into the sockets of the fuel pump (4) and the fuel feed intermediate pipe (5). Take care not to hit the 2 formed ends (3) of the fuel feed intermediate pipe (1) on the threaded sockets of the fuel pump (4) and fuel feed intermediate pipe (5).
- Hold the fuel feed intermediate pipe (1) firmly in place and hand tighten the 2 fuel feed intermediate pipe nuts (2).
- Fuel Feed Intermediate Pipe Nut (2) - Tighten [ 2x ] - Fastener Specifications
Fuel Feed Pipe (2) - Install
- Fuel Feed Pipe (2) - Connect - Metal Collar Quick Connect Fitting Service
- Fuel Feed Pipe Bolt (1) - Install and tighten - Fastener Specifications
Fuel Feed Pipe (1) - Install
- Fuel Feed Pipe (1) - Connect - Metal Collar Quick Connect Fitting Service
- 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 Pump Insulator (1) - Install
- Remove the covers from the cylinder head passages.
Intake Manifold Gasket (1) - Install NEW [ 8x ]
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.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Position the intake manifold and Intake manifold cover (1) to install harness retainers.
Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) - Install [ 4x ]
- Move the intake manifold and intake manifold cover (2) into place.
- NOTE:
Some components not shown for graphic clarity.
Intake Manifold Bolt (1) - Hand tighten [ 10x ]
- Intake Manifold Bolt (1) - Tighten in sequence [ 10x ] - Fastener Specifications
Positive Crankcase Ventilation Tube Connector (2) @ Intake Manifold - Install - Plastic Collar Quick Connect Fitting Service
Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) - Install [ 3x ]
Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) - Install [ 4x ]
Engine Wiring Harness Connector (4) @ Evaporative Emission Canister Purge Solenoid Valve - Connect
- Engine Wiring Harness Connector (3) @ Manifold Absolute Pressure Sensor - Connect
- Engine Wiring Harness Retainer (2) @ Intake Manifold Cover - Install [ 2x ]
- Engine Wiring Harness Connector (1) @ Throttle Body - Connect
Evaporative Emission Canister Purge Tube (2) @ Evaporative Emission Canister Purge Solenoid Valve - Install
- Evaporative Emission Canister Purge Tube Connector (1) @ Evaporative Emission Canister Purge Solenoid Valve - Engage - Plastic Collar Quick Connect Fitting Service
Plenum Front Panel Outer Reinforcement (1) - Install - Plenum Front Panel Outer Reinforcement Removal and Installation
Air Cleaner Outlet Duct (3) - Install
- Air Cleaner Outlet Duct Clamp (2) - Tighten [ 2x ] - Fastener Specifications
- Positive Crankcase Ventilation Fresh Air Tube (1) - Connect - Plastic Collar Quick Connect Fitting Service
Air Cleaner Outlet Duct Bracket Bolt (1) - Install and tighten - Fastener Specifications
- Install engine wiring harness to air cleaner outlet duct bracket.
- Start the engine and check for fuel leaks.
Refer to Component Fastener Tightening Caution .
Refer to Fastener Caution .
Start the fuel injection fuel rail bolts by hand then draw the injector rail down evenly prior to tightening.
Alternately hand-tighten the fuel pump bolts one turn at a time until the pump is fully seated. Trying to draw down the pump without even side-to-side tightening may result in pump plunger damage.
The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness.