Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Installation Procedure
- NOTE:
The fuel injector seal spacer is directional. If installed in the incorrect orientation, a fuel leak can result. When installed correctly, the fuel injector seal spacer will be flush with the injector.
Fuel Injector Seal Spacer (1) - Install NEW [4x]
- Fuel Injector Seal (2) - Install NEW [4x]
- Fuel Injector Bushing (3) - Install [4x]
Holding the largest diameter/body (2) of the injector only, insert the injector assembly (2) into the fuel rail. Ensure correct orientation of the electrical connector.
- Fuel Injector Retainer (1) - Install NEW [4x]
- NOTE:
DO NOT use any type of lubricant when installing the NEW combustion seals on the fuel injector tip.
Install EN-51955-1 Long Protector (1) onto the fuel injector tip, covering the first recessed area closest to the tip. Place a NEW fuel injector nozzle housing seal (2) on EN-51955-1 Long Protector (1).
- Using EN-51955-4 Pusher (3), install the fuel injector nozzle housing seal (2) into the recessed area (4) of the fuel injector, then remove the EN-51955-1 Long Protector.
- Compress the fuel injector nozzle housing seal (2) using EN-51955-3 Pre-Sizer (5).
- Using EN-51955-5 Sizer (6), resize the fuel injector nozzle housing seal.
- Install EN-51955-2 Short Protector (7) onto the fuel injector tip. Place a second NEW fuel injector nozzle housing seal (8) on EN-51105-2 Short Protector (7).
- Using EN-51955-4 Pusher (3), install the fuel injector nozzle housing seal (8) into the remaining recessed area (9) of the fuel injector, then remove EN-51105-2 Short Protector.
- Compress the fuel injector nozzle housing seal (8) using EN-51955-3 Pre-Sizer (5).
- Using EN-51955-5 Sizer (6), resize the fuel injector nozzle housing seal.
- NOTE:
The fuel injector nozzle housing seals must fit properly in the relative groove. Overlapping of the fuel injector nozzle housing seals with the external surface of the injector must be avoided.
Check both of the fuel injector nozzle housing seals on each fuel injector for correct seat:
- The fuel injector nozzle housing seal must not be too large, buckled, or corrugated (1)
- The fuel injector nozzle housing seal must be fixed tight and accurate (2)
- If the fuel injector nozzle housing seals are not installed correctly, remove the incorrect fuel injector nozzle housing seal and replace with a NEW fuel injector nozzle housing seal.
- NOTE:
Hand place the fuel injection fuel rail into the position on the cylinder head.
Fuel Injection Fuel Rail (1) - Move into position
- Fuel Injection Fuel Rail Bolt (2) - Install and hand tighten [4x]
- Tighten the 2 outer fuel injection fuel rail bolts (2) by alternating in steps of 1/2 turn, until the fuel injection fuel rail (1) is fully seated.
- Fuel Injection Fuel Rail Bolt (2) - Tighten [4x] - Fastener Specifications
- Connect the 3 electrical connectors (3).
Fuel Feed Intermediate Pipe (2) - Install NEW
- Fuel Injection Fuel Feed Pipe Bracket Bolt (1) - Install and tighten - Fastener Specifications
Nut @ Fuel Feed Intermediate Pipe (1) - Tighten [2x] - Fastener Specifications
Electrical Connector (1) - Connect as necessary
- 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
Engine Coolant Flow Control Valve Seal (2) - Install NEW
- Install the engine coolant flow control valve and thermostat bypass hose (1) to the exhaust manifold coolant outlet pipe (3) then position the engine coolant flow control valve to the engine block.
Engine Coolant Flow Control Valve Bolt (1) - Install and tighten [5x] - Fastener Specifications
Engine Coolant Temperature Sensor Electrical Connector (2) @ Engine Coolant Flow Control Valve - Connect
- Electrical Connector (1) @ Engine Coolant Flow Control Valve - Connect [2x]
Slide the hose clamp (3) back into position and engage the clamp. Hose Clamp Replacement Guidelines - Spring Type
- Thermostat Bypass Hose (2) @ Engine Coolant Flow Control Valve - Install
- Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Radiator Inlet Hose (4) @ Engine Coolant Flow Control Valve - Install
- Engine Oil Cooler Coolant Inlet Hose (3) @ Engine Coolant Flow Control Valve - Install
- Engine Coolant Flow Control Valve Hose (2) @ Engine Coolant Flow Control Valve - Install
- Hose Clamp (1) - Engage [3x] - Hose Clamp Replacement Guidelines - Spring Type
Crankcase Vent Passage Seal (1) - Install NEW
Intake Manifold Gasket (1) - Install NEW [4x]
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
- Reposition the wiring harness.
Wiring Harness Retainer (1) - Install [2x]
Retainer (1) - Install [2x]
Reposition the battery cable and channel (1) over the intake manifold.
Wiring Harness Retainer (2) - Install [3x]
- Wiring Harness Retainer (1) - Install [2x]
Engine Harness Retainer (2) - Install
- Connect the electrical connectors.
- Intake Air Pressure and Temperature Sensor (3)
- Throttle Body (4)
- Intake Manifold Cover Bolt (1) - Install and tighten [2x] - Fastener Specifications
Wiring Harness Retainer (1) - Install [3x]
Evaporative Emission Canister Purge Pump (2) - Install
- Evaporative Emission Canister Purge Pump Bolt (1) - Install and tighten [3x] - Fastener Specifications
Wiring Harness Retainer (1) @ Evaporative Emission Canister Purge Pump Bracket (2) - Install
Evaporative Emission Canister Purge Tube (3) - Install - Plastic Collar Quick Connect Fitting Service
- Evaporative Emission Canister Purge Tube (2) - Connect - Plastic Collar Quick Connect Fitting Service
- Fuel Feed Pipe Bolt (1) - Install and tighten - Fastener Specifications
- Connect the evaporative emission canister purge pump electrical connector.
Rotate the oil level indicator tube (2) into the installed position.
- Oil Level Indicator Tube Bracket Bolt (1) - Install and tighten - Fastener Specifications
Charge Air Cooler Outlet Air Hose (2) - Install
- Retainer Spring (1) - Engage
Air Cleaner Assembly (2) - Install
- Air Cleaner Nut (1) - Install and tighten - Fastener Specifications
- Connect the mass airflow sensor electrical connector.
- Install wiring harness to air cleaner assembly.
Intake Air Duct (2) - Install
- Intake Air Duct Retainer (1) - Install
Intake Air Splash Shield (2) - Install
- Intake Air Baffle Retainer (1) - Install [10x]
Hood Secondary Latch Release Handle (2) - Install
- Hood Latch Actuator Bolt (1) - Install and tighten [2x] - Fastener Specifications
Positive Crankcase Ventilation Tube (1) - Install - Plastic Collar Quick Connect Fitting Service
- Connect the battery negative cable. Battery Negative Cable Disconnection and Connection (Without KL9) , or Battery Negative Cable Disconnection and Connection (With KL9)
- Fill the cooling system. Cooling System Draining and Filling (GE 47716 L3B) , or Cooling System Draining and Filling (Static L3B)
- Inspect for fuel leaks using the following procedure:
- Turn ON the ignition with the engine OFF for 2 seconds.
- Turn OFF the ignition for 10 seconds.
- Turn ON the ignition with the engine OFF.
- Inspect for fuel leaks.
Arrows show proper orientation to install the bushing. Will fit flush against the injector.
Refer to Fastener Caution .
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.