GM 3.6L Truck 2010-11

1 Description and Operation

1.1 Gasoline Direct Injection

1.1.1 General Overview

Gasoline Direct Injection (GDI) is characterized by a high-pressure fuel injection directly into the combustion chamber.

Low Pressure fuel is supplied from the fuel tank by an electrically operated fuel pump at a pre-delivery pressure of 3 to 5 bar (43 to 73 psi) to the high-pressure pump.

The high-pressure pump compresses the fuel up to 350 bar (5076 psi), depending on the load and speed of the engine.

The fuel is stored in the fuel rail and sprayed into the combustion chamber through electrically operated high-pressure fuel injectors.

The Engine Control Module (ECM) utilizes a pressure sensor mounted on the fuel rail to adjust the high side fuel pressure by means of a pressure control valve mounted on the high-pressure pump.

1.1.2 High-Pressure Pump

Features

  • Demand controlled single plunger pump

  • System pressure up to 350 bar (5076 psi)

  • Mounting on cylinder head or adapter flange

  • Compact shape, light weight, fuel compatibility, stainless steel body and internal components

  • Integrated pressure damper allows variable feed pressure

  • Integrated pressure relief valve

  • Flexible customer interface concept

  • ZEVAP suitable (no O-ring-seals)

  • w/o leakage or pressure damper ventilation line

  • Two welded hydraulic connectors (HP, LP non twistable)

The high fuel pressure necessary for direct injection is supplied by the high pressure fuel pump. The pump is mounted on the engine and is driven by lobe(s) on the camshaft. This pump also regulates the fuel pressure using an actuator in the form of an internal solenoid-controlled valve. In order to keep the engine running efficiently under all operating conditions, the engine control module (ECM) requests pressure ranging from 2 to 15 MPa (290 to 2176 psi), depending on engine speed and load.

Output drivers in the control module provide the pump control circuit with a 12 V pulse-width modulated (PWM) signal, which regulates fuel pressure by closing and opening the control valve at specific times during pump strokes. This effectively regulates the portion of each pump stroke that is delivered to the fuel rail. When the control solenoid is NOT powered, the pump operates at maximum flow rate. In the event of pump control failure, the high pressure system is protected by a relief valve in the pump.

1.1.3 High-Pressure Solenoid Injector

The fuel injection system is a high pressure, direct injection, returnless on-demand design. The fuel injectors are mounted in the cylinder head and spray fuel directly into the combustion chamber. Direct injection requires high fuel pressure due to the fuel injector's location in the combustion chamber. Fuel pressure must be higher than compression pressure requiring a high pressure fuel pump. The fuel injectors also require more electrical power due to the high fuel pressure. The control module supplies a separate high voltage supply circuit and a high voltage control circuit for each fuel injector. The injector high voltage supply circuit and the high voltage control circuit are both controlled by the control module. The control module energizes each fuel injector by grounding the control circuit. The control module controls each fuel injector with 65 V. This is controlled by a boost capacitor in the control module. During the 65 V boost phase, the capacitor is discharged through the injector, allowing for initial injector opening. The injector is then held open with 12 V.

The fuel injector assembly is an inside opening electrical magnetic injector. The injector has six precision machined holes that generate a cone shaped oval spray pattern. The fuel injector has a slim extended tip in order to allow a sufficient cooling jacket in the cylinder head.

1.1.4 Fuel Rail

The fuel rail serves to store the fuel delivered by the high pressure pump and distribute it to the high pressure injectors. The rail is made larger and thicker to compensate for pressure pulses and to tolerate the higher fuel pressures. A pressure sensor is located on the fuel rail.

1.1.5 Fuel Rail Pressure Sensor

The fuel rail pressure sensor detects fuel pressure within the fuel rail. The engine control module (ECM) provides a 5 V reference voltage on the 5 V reference circuit and ground on the low reference circuit. The ECM receives a varying signal voltage on the signal circuit. The ECM monitors the voltage on the fuel rail pressure sensor circuits. When the fuel pressure is high, the signal voltage is high. When the fuel pressure is low, the signal voltage is low.

The high side fuel pressure may be as high as 350 bar (5076 psi) depending on the engine type and load conditions.

If the high side fuel pressure sensor should fail, the fuel pressure regulating valve is activated by the ECM at a fixed value.

2 Safety Instructions

2.1 General Safety Instructions

2.1.1 Voltage

On vehicles with direct gasoline injection, the high-pressure injectors are actuated with hazardous voltages of up to 120 volts. Contact with live terminals or wires can prove fatal. Despite insulation, flashover can cause electric shock. Use vehicle specific adapter leads to perform test connections. Do not disconnect electrical connections to the high-pressure fuel injectors with the engine running.

2.1.2 Fuel Pressure

Fuel under high pressure can cause serious skin and eye injuries. The highly vaporized fuel is also extremely flammable. Before testing and/or replacing components on the high-pressure side of the fuel system, always start by reducing the residual fuel pressure in accordance with the vehicle manufacturer instructions. Special procedures and tools are required for the removal of injectors.

3 Diagnosis

3.1 Diagnostic Fault Information

3.1.1 DTC P0087 or P0088

DTC Description
P0087

Fuel rail pressure too low

P0088

Fuel rail pressure too high

3.1.1.1 Description

The fuel rail pressure sensor is a three wire sensor that detects pressure in the fuel rail. The control module supplies a 5 volt reference voltage and ground to the sensor. The pressure signal is sent back to the control module via the signal wire.

3.1.1.2 Possible Causes

  • Defect in wiring harness between control module and rail-pressure sensor

  • Defective fuel rail-pressure sensor

  • Defect in high-pressure system

  • Defective control module

3.1.1.3 Actions

  • Check wiring harness between pressure sensor and control module

  • Replace defective pressure sensor

  • Repair high pressure fuel system

  • Replace control module

3.1.2 DTC P0089, P0090, P0091 or P0092

DTC Description
P0089

Fuel pressure regulator performance

P0090

Fuel pressure regulator control circuit

P0091

Fuel pressure regulator solenoid 1 control circuit low voltage

P0092

Fuel pressure regulator solenoid 1 control circuit high voltage

3.1.2.1 Description

The fuel pressure regulator is a two wire Pulse Width Modulated (PWM) solenoid which is part of the high pressure fuel pump.

The fuel rail pressure sensor provides feedback necessary for the control module to control the high pressure fuel. With the engine running at idle, the actual fuel rail pressure should be close to 508-798 psi (3.5-5.5 MPa) .

3.1.2.2 Possible Causes

  • Defect in wiring harness between control module and rail-pressure sensor

  • Defective rail-pressure sensor

  • Defective control module

3.1.2.3 Actions

  • Check wiring harness between pressure sensor and control module

  • Replace defective fuel pressure regulator (part of high pressure fuel pump)

  • Replace control module

3.1.3 DTC P0190–P0194

DTC Description

P0190

Fuel Rail Pressure (FRP) sensor circuit

P0191

Fuel Rail Pressure (FRP) sensor circuit range/performance

P0192

Fuel Rail Pressure (FRP) sensor circuit low voltage

P0193

Fuel Rail Pressure (FRP) sensor circuit high voltage

P0194

Fuel Rail Pressure (FRP) sensor circuit Intermittent

3.1.3.1 Description

The Fuel Rail Pressure (FRP) sensor is a three wire sensor that detects pressure in the fuel rail. The control module supplies a 5 volt reference voltage and ground to the sensor. The pressure signal is sent back to the control module via the signal wire.

The FRP sensor is mounted in the fuel rail and provides feedback to the control module for control of the high pressure fuel. With the engine running at idle, the actual fuel rail pressure should be close to 508-798 psi (3.5-5.5 MPa) .

3.1.3.2 Possible Causes

  • Defect in wiring harness between control module and fuel rail pressure sensor

  • Defective fuel rail pressure sensor

  • Defective control module

3.1.3.3 Actions

  • Check wiring harness between pressure sensor and control module

  • Replace defective fuel pressure regulator (part of high pressure fuel pump)

  • Replace control module

3.1.4 DTC P0201-P0208 or P0261–P0284

DTC Description

P0201

Injector 1 control circuit open

P0202

Injector 2 control circuit open

P0203

Injector 3 control circuit open

P0204

Injector 4 control circuit open

P0205

Injector 5 control circuit open

P0206

Injector 6 control circuit open

P0207

Injector 7 control circuit open

P0208

Injector 8 control circuit open

P0261

Injector 1 control circuit low voltage

P0262

Injector 1 control circuit high voltage

P0263

Injector 1 contribution/balance

P0264

Injector 2 control circuit low voltage

P0265

Injector 2 control circuit high voltage

P0266

Injector 2 contribution/balance

P0267

Injector 3 control circuit low voltage

P0268

Injector 3 control circuit high voltage

P0269

Injector 3 contribution/balance

P0270

Injector 4 control circuit low voltage

P0271

Injector 4 control circuit high voltage

P0272

Injector 4 contribution/balance

P0273

Injector 5 control circuit low voltage

P0274

Injector 5 control circuit high voltage

P0275

Injector 5 contribution/balance

P0276

Injector 6 control circuit low voltage

P0277

Injector 6 control circuit high voltage

P0278

Injector 6 contribution/balance

P0279

Injector 7 control circuit low voltage

P0280

Injector 7 control circuit high voltage

P0281

Injector 7 contribution/balance

P0282

Injector 8 control circuit low voltage

P0283

Injector 8 control circuit high voltage

P0284

Injector 8 contribution/balance

3.1.4.1 Description

The control module supplies voltage to each fuel injector on the positive control circuits and energizes each fuel injector by grounding the negative circuit. The control module monitors the status of the fuel injector control. When a problem with a fuel injector circuit is detected, the control module will disable the affected fuel injector.

3.1.4.2 Possible Causes

  • Defect in wiring harness between control module and fuel injector

  • Defective fuel injector

  • Defective control module

3.1.4.3 Actions

  • Check wiring harness between fuel injector and control module for opens, shorts to power or ground

  • Replace defective fuel injector

  • Replace control module

3.1.5 DTC P0300-P0308

DTC Description
P0300

Random misfire detected

P0301

Misfire cylinder 1 detected

P0302

Misfire cylinder 2 detected

P0303

Misfire cylinder 3 detected

P0304

Misfire cylinder 4 detected

P0305

Misfire cylinder 5 detected

P0306

Misfire cylinder 6 detected

P0307

Misfire cylinder 7 detected

P0308

Misfire cylinder 8 detected

3.1.5.1 Description

The control module uses information from the Crankshaft Position (CKP) sensor to determine when an engine misfire occurs and uses information from the Camshaft Position (CMP) sensor to determine which cylinder is misfiring.

3.1.5.2 Possible Causes

  • Defective air/fuel mixture

  • Defective fuel injector

  • Defective ignition system

  • Engine mechanical defect

3.1.5.3 Actions

  1. Check for and repair other DTCs first.

  2. Run engine at idle and listen for abnormal mechanical noise. Diagnose and repair mechanical issues first.

  3. Verify that the following conditions do not exist:

  • Engine vacuum leaks

  • Moisture in ignition system

  • Broken/Cracked spark plug insulator

  • Fuel pressure that is too low or too high

  • Contaminated fuel

  • Restricted exhaust system

3.1.6 Sub System Schematic

 

3.1.7 Connector End Views

Figure 1: ECM C1 Connector
Figure 2: Fuel Injector Connector
Figure 3: Fuel Rail Pressure Sensor Connector
Figure 4: High-pressure Fuel Pump Connector

4 Removal and Installation

4.1 Fuel Pressure Relief

4.1.1 Fuel Pressure Relief

warning:

Fuel that flows out at high pressure can cause serious injury to the skin and eyes. ALWAYS depressurize the fuel system before removing components that are under high fuel pressure.

Fuel Pressure Relief

  1. Remove the fuel pump 20A fuse from the underhood electrical center.

  2. Start the vehicle and allow the engine to run until it stalls. It may take 20–30 seconds for the engine to stall from lack of fuel.

  3. The pressure in the fuel lines has been reduced to a safe level.

  4. Turn the ignition key to OFF.

4.2 Fuel Rail Assembly

4.2.1 Fuel Rail Assembly

Removal Procedures

  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.

  2. Remove the fuel pipe shield. Refer to Fuel Pipe Shield.

  3. Remove the intake manifold. Refer to Intake ManifoldIntake Manifold.

    warning:

    Fuel that flows out at high pressure can cause serious injury to the skin and eyes. ALWAYS depressurize the fuel system before removing components that are under high fuel pressure.

  4. Relieve the fuel system pressure. Refer to Fuel Pressure Relief

  5. Remove and discard the high pressure fuel pipe. Refer to High Pressure Fuel Pipe.

  6. Remove and discard the fuel rail crossover pipe. Refer to Fuel Rail Crossover Tube.

  7. Remove the intake gasket (1) and foam insulator (2) from the fuel rails.

  8. Remove the bank 2 fuel injection rail. Refer to .

  9. Disconnect the fuel pressure sensor electrical connector, cut the wire harness tie straps and move the wiring out of the way.

  10. Remove the fuel rail bolts (1) from both rails (2), for clearance purposes.

  11. Remove the fuel rail from the cylinder head.

  12. Remove and discard the fuel injector hold down clamps.

  13. Once the fuel rail is removed, remove the fuel injectors and rebuild them. Refer to Fuel Injector.

Installation Procedure

  1. Install the fuel injectors with new seals in the cylinder heads. Refer to Fuel Injector.

  2. Install NEW injector hold down clamps on each fuel injector.

  3. On a new fuel rail, lubricate the fuel injector cups with silicon free engine oil.

  4. Carefully place fuel rail (2) over injectors and install the fuel rail mounting bolts (1).

    1. First tighten the fuel rail bolts to 106 in. lb. (12 Nm).

    2. Finally tighten the fuel rail bolts to 18 ft. lbs. (24 Nm).

  5. Connect the electrical connectors to the fuel injectors.

  6. Install a new high pressure fuel pipe. Refer to High Pressure Fuel Pipe.

  7. Install a new fuel rail crossover tube. Refer to Fuel Rail Crossover Tube

  8. Connect the electrical connector to the fuel rail pressure sensor.

  9. Install the foam insulator (2) over the fuel rails and new gasket (1) over the intake ports.

  10. Install the intake manifold. Refer to Intake Manifold.

  11. Install the fuel pipe shield. Refer to Fuel Pipe Shield.

  12. Pressurize the fuel system and check for leaks.

4.3 Fuel Injector

4.3.1 Fuel Injector

Removal

  1. Relieve the high side fuel system pressure. Refer to Fuel Pressure Relief.

  2. Disconnect the air duct from the throttle body.

  3. Remove the fuel pipe shield. Refer to Fuel Pipe Shield

  4. Disconnect the electrical connector (5) from the throttle body.

  5. Remove the 10mm bolt (2) for the wiring harness bracket.

  6. Remove plastic harness clamp from metal bracket at rear of right cylinder head.

  7. Remove PCV valve and hose (1) from intake manifold.

  8. Remove insulation cover (4) from top of intake manifold.

  9. Remove the 6 mounting bolts (1) and remove intake manifold (2).

  10. Remove gasket (1) and foam insulator (2) from top of fuel rails.

  11. Disconnect electrical connector from fuel rail pressure sensor.

  12. Remove high pressure fuel pipe (1), and fuel rail crossover pipe (2) from fuel rails.

  13. Remove the fuel rail bolts (1). Carefully lift the fuel rail (2) and disconnect the top of the injectors from the fuel rail.

  14. Disconnect the electrical connectors from the fuel injectors.

  15. Use EN-37281-Ainjector remover or equivalent to extract injectors if necessary. See fuel injector removal video. Click here to purchase special tools

Installation

  1. Clean the injector bore using EN-47909Cleaning Kit or equivalent. See injector bore cleaning video.

  2. Place appropriate Injector Seal Installer (1) from EN-48266Injector Seal Sizer/Installer or equivalent over the bottom of the fuel injector. Slide the new Teflon seal (2) over the installer and into the groove on the fuel injector (3). Remove the tapered seal installer. See Teflon seal installation video..

  3. Place Injector Seal Sizer (1) from EN-48266Injector Seal Sizer/Installer or equivalent over the Teflon seal (2) until it stops. Turn the sizer one half turn in each direction to compress the seal and remove the tool from the fuel injector (3).

  4. Install a new plastic spacer (2) and O-ring (1) at the top of the fuel injector. Lubricate the O-ring with silicon free engine oil.

  5. Carefully place fuel rail over injectors and install the fuel rail mounting bolts.

    1. First tighten the fuel rail bolts to 106 in. lb. (12 Nm).

    2. Finally tighten the fuel rail bolts to 18 ft. lbs. (24 Nm).

  6. Connect the electrical connectors to the fuel injectors.

  7. Install a new high pressure fuel pipe. Refer to High Pressure Fuel Pipe.

  8. Install a new fuel rail crossover tube. Refer to Fuel Rail Crossover Tube

  9. Connect the electrical connector to the fuel rail pressure sensor.

  10. Install the foam insulator (2) over the fuel rails and gasket (1) over the intake ports.

  11. Install the intake manifold. Tighten bolts evenly to 18 ft. lbs. (24 Nm) in a criss-cross pattern.

  12. Place insulation on intake manifold.

  13. Install PCV valve and hose (1) on intake manifold.

  14. Install plastic harness clamp on metal bracket at rear of right cylinder head.

  15. Install the 10mm bolt (2) for the wiring harness bracket.

  16. Connect the electrical connector (5) to the throttle body.

  17. Install the fuel pipe shield. Refer to Fuel Pipe Shield

  18. Connect the air duct to the throttle body.

  19. Pressurize the fuel system and check for leaks.

4.4 Fuel Rail Crossover Tube

4.4.1 Fuel Rail Crossover Tube

Removal

  1. Remove the fuel pipe shield. Refer to Fuel Pipe Shield

  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.

  3. Loosen the fuel rail crossover pipe (2) fitting from the right and left fuel rails.

  4. Remove the fuel rail crossover pipe (2) from the engine. Discard the pipe.

Installation

  1. Obtain a new fuel rail crossover pipe.

  2. Clean and dry the fuel rail crossover pipe, and fuel rail fittings prior to assembly.

  3. Lubricate the fittings with silicon free engine oil or equivalent. Prevent oil from entering fuel system.

  4. Position the fuel rail crossover pipe (2) in the fuel rail fittings. Tighten the tube nuts finger tight.

  5. Tighten the fuel rail crossover pipe fittings as follows;

    1. First tighten the fittings to 12 ft. lbs. (16 Nm).

    2. Finally tighten the fittings to 24 ft. lbs. (32 Nm).

  6. Pressurize the fuel system by turning the ignition to ON.

  7. Inspect the fuel system for leaks. Replace leaking component if necessary.

  8. Install the fuel pipe shield. Refer to Fuel Pipe Shield

4.5 Fuel Pump

4.5.1 Fuel Pump

Removal

  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.

  2. Remove the thermostat housing. Refer to Engine Coolant Thermostat.

  3. Disconnect the electrical connector from the high pressure fuel pump (4).

  4. Remove and discard the low pressure feed pipe (3). Refer to Fuel Feed Pipe.

  5. Remove and discard the high pressure pipe (2). Refer to High Pressure Fuel Pipe.

  6. Remove and discard the high pressure fuel pump bolts (1).

  7. Remove the high pressure fuel pump (4).

  8. Remove and discard the fuel pump O-ring.

  9. Remove and discard the fuel pump gasket.

  10. Remove the high pressure fuel pump roller lifter.

Installation

note:

The camshaft must be in the base circle position before the high pressure fuel pump is installed.

  1. Use the EN-48896alignment gauge to ensure that the camshaft lobe is in the base circle position. At base circle the tool will be flush with the head. Click Here to Purchase Special Tools

  2. Lubricate the high pressure fuel pump cylinder head bore and roller lifter with camshaft prelube or equivalent.

    note:

    The high pressure fuel pump gasket has a retaining feature to hold the pump retaining bolts in place.

  3. Install the roller lifter in the cylinder head.

  4. Install a NEW O-ring on the high pressure fuel pump.

  5. Position the NEW high pressure fuel pump gasket and bolts (1) to the fuel pump.

  6. Install the high pressure fuel pump (4). Force will be required while hand tightening the bolts.

  7. Tighten the high pressure fuel pump retaining bolts to 11 ft. lbs. (15 Nm).

  8. Ensure the high pressure fuel pump and fuel rail fittings are clean prior to assembly.

  9. Install a NEW high pressure fuel pipe (2). Refer to High Pressure Fuel Pipe.

  10. Install a NEW fuel feed pipe (3) to the high pressure fuel pump (4). Refer to Fuel Feed Pipe.

  11. Connect the electrical connector to the high pressure fuel pump.

  12. Install the thermostat housing. Refer to Engine Coolant Thermostat.

    note:

    If a fuel leak occurs at the fuel rail, the fuel rail will need to be replaced.

  13. Pressurize the fuel system by turning the ignition to ON.

  14. Inspect the fuel system for leaks.

4.6 Fuel Pressure Sensor

4.6.1 Fuel Rail Pressure Sensor

Removal

  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.

  2. Remove the intake manifold and gasket. Refer to Intake Manifold.

  3. Remove the foam insulator from the fuel rails.

    note:

    Applying force to the plastic housing of the sensor will destroy the sensor. To tighten or loosen, only apply force to the attached hexagon.

  4. Disconnect the fuel pressure sensor electrical connector (1).

  5. Using a 27 mm socket, remove the fuel pressure sensor (2) from the fuel injection fuel rail (3). Discard the fuel pressure sensor.

  6. Clean and dry the sealing cone in the fuel rail with a lint free cloth.

Installation

  1. Lubricate the threads of the sensor with a small amount of silicon free engine oil.

  2. Install the NEW fuel pressure sensor (2) to the fuel rail (3) hand tight. Then tighten the sensor to 33 Nm (25 lb ft).

  3. Connect the electrical connector (1) to the fuel pressure sensor .

  4. Install the foam insulator on the fuel rails.

  5. Install the intake manifold. Refer to Intake Manifold.

  6. Pressurize the fuel system and check for leaks.

4.7 Fuel Pipe Shield

4.7.1 Fuel Pipe Shield

Removal

  1. Remove the throttle body air duct as needed.

  2. Remove the bolt and the fuel pipe shield.

Installation

  1. Install the fuel pipe shield. Tighten bolt to 89 in. lbs. (10 Nm).

  2. Install the air duct to the throttle body if removed.

4.8 Fuel Feed Pipe

4.8.1 Fuel Feed Pipe

Removal

  1. Remove the air duct from the throttle body.

  2. Remove the fuel pipe shield. Refer to Fuel Pipe Shield

  3. Remove the high pressure pump shield. Refer to Fuel Pump.

  4. Relieve the low side fuel system pressure. Refer to Fuel Pressure Relief.

  5. Disconnect the fuel feed line quick connect fitting from the fuel feed pipe (3).

  6. Unbolt the fuel feed pipe from the cylinder head.

  7. Loosen the fuel feed pipe fitting to the high pressure fuel pump. Remove and discard the pipe.

Installation

  1. Ensure that the fuel feed pipe and fuel pump fittings are clean and dry.

  2. Lubricate the pipe threads with silicon free engine oil or equivalent.

  3. Position the NEW fuel feed pipe (3) to the cylinder head and high pressure fuel pump. Screw the fitting into the pump finger tight.

    1. Tighten the bolt on the cylinder head to 37 ft. lbs. (50 Nm).

    2. Tighten the fitting to 20 ft. lbs. (28 Nm).

  4. Connect the fuel feed line quick connect fitting to the fuel feed pipe (3).

  5. Install the fuel pump shield. Refer to Fuel Pump

  6. Pressurize the system and check for leaks.

  7. Install the fuel pipe shield. Refer to Fuel Pipe Shield.

  8. Install the air duct to the throttle body.

4.9 High Pressure Fuel Pipe

4.9.1 High Pressure Fuel Pipe

Removal

  1. Remove the air duct from the throttle body.

  2. Remove the fuel pipe shield. Refer to Fuel Pipe Shield

  3. Relieve fuel system pressure. Refer to Fuel Pressure Relief.

  4. Remove the foam insulator from the pipes.

  5. Loosen the high pressure pipe (1) fitting to the high pressure fuel pump.

  6. Loosen the high pressure pipe fitting at the fuel rail.

  7. Remove and discard the high pressure fuel pipe (1) from the engine.

Installation

  1. Make sure the threads and fittings are clean and dry.

  2. Lubricate the threads with a small amount of silicon free engine oil or equivalent.

  3. Position a NEW high pressure fuel pipe (1) to the fuel pump fitting and fuel rail. Tighten the fittings finger tight.

  4. Tighten the high pressure fuel pipe fittings using the following steps.

    1. First tighten the fitting to 12 ft. lbs. (16 Nm).

    2. Then tighten the fitting to 24 ft. lbs. (32 Nm).

  5. Pressurize the fuel system and check for leaks.

  6. Install the fuel pipe shield. Refer to Fuel Pipe Shield.

  7. Connect the air duct to the throttle body.

4.10 Intake Manifold

4.10.1 Intake Manifold

Removal

  1. Relieve the high side fuel system pressure. Refer to Fuel Pressure Relief.

  2. Disconnect the air duct from the throttle body.

  3. Remove the fuel pipe shield. Refer to Fuel Pipe Shield

  4. Disconnect the electrical connector (5) from the throttle body.

  5. Remove the 10mm bolt (2) for the wiring harness bracket.

  6. Remove plastic harness clamp from metal bracket at rear of right cylinder head.

  7. Remove PCV valve and hose (1) from intake manifold.

  8. Remove insulation cover (4) from top of intake manifold.

  9. Remove the 6 mounting bolts (1) and remove intake manifold (2).

  10. Remove gasket (1) from the intake ports.

Installation

  1. Install a new gasket (1) over the intake ports.

  2. Install the intake manifold. Tighten bolts evenly to 18 ft. lbs. (24 Nm) in a criss-cross pattern.

  3. Place insulation (4) on intake manifold.

  4. Install PCV valve and hose (1) on intake manifold.

  5. Install plastic harness clamp on metal bracket at rear of right cylinder head.

  6. Install the 10mm bolt (2) for the wiring harness bracket.

  7. Connect the electrical connector (5) to the throttle body.

  8. Install the fuel pipe shield. Refer to Fuel Pipe Shield

  9. Connect the air duct to the throttle body.

  10. Pressurize the fuel system and check for leaks.

4.11 Engine Coolant Thermostat

4.11.1 Engine Coolant Thermostat

Removal

  1. Partially drain the cooling system to a level below the thermostat housing.

  2. Remove the throttle body air duct.

  3. Remove the fuel pipe shield. Refer to Fuel Pipe Shield.

  4. Disconnect the hoses from the thermostat housing.

  5. Remove the thermostat housing mounting bolts.

  6. Remove the thermostat housing. Discard the gasket.

Installation

  1. Clean the sealing surfaces.

  2. Install the thermostat housing with a new gasket.

  3. Tighten large bolt to 37 ft. lbs. (50 Nm) and smaller housing bolts to 89 in. lbs. (10 Nm).

  4. Connect the hoses to the thermostat housing.

  5. Install the fuel pipe shield. Refer to Fuel Pipe Shield.

  6. Install the throttle body air duct.

  7. Refill the cooling system.

  8. Check the cooling system for leaks.

5 Component Testing

5.1 Fuel Injector Balance Test

5.1.1 Fuel Injector Balance Test with Active Fuel Injector Tester - Preferred Method

  1. Verify the battery is fully charged and all accessories are OFF.

  2. Ignition OFF, all vehicle systems OFF. Install the CH-47976Active Fuel Injector Tester as instructed in the user manual. Click here to purchase special tools

  3. Turn ON the Active Fuel Injector Tester and select the vehicle.

  4. Turn ignition ON; perform the Injector Test with the Active Fuel Injector Tester.

  5. Compare the test results with the appropriate recommended tolerance.

5.1.2 Fuel Injector Balance Test with Scan Tool

  1. Verify the correct low side fuel pressure.

  2. Engine idling; verify the scan tool Fuel Rail Pressure Sensor parameter is approximately to 508-798 psi (3.5-5.5 MPa).

    note:

    The engine speed must be between 600–1000 RPM to perform this test.

  3. Select the Fuel Injector Balance function on the scan tool.

  4. Select and test an injector. Repeat for each injector.

  5. Obtain and record a pressure drop value for each injector.

  6. Add all individual pressure drop values except for the injector suspected of being faulty. This is the total pressure drop.

  7. Divide the total pressure drop by the number of fuel injectors that were added together. This is the average pressure drop.

  8. Multiply the average pressure drop by 0.20. This is the acceptable variance from the average pressure drop, 20 percent.

  9. Verify that the difference between any individual pressure drop and the average pressure drop is not greater than the acceptable variance. Replace the injector if outside of acceptable variance.

6 Special Tools

6.1 Special Tools

6.1.1 Special Tools

6.1.1.1 Active Fuel Injector Tester CH-47976

6.1.1.2 Alignment Gauge EN-48896

6.1.1.3 Alignment Gauge EN-50790

6.1.1.4 Cotton Swabs EN-47909–20

6.1.1.5 Flywheel Holding Tool EN-50792

6.1.1.6 Impact Hammer 307–005

6.1.1.7 Injector Bore Brush 310–205

6.1.1.8 Injector Bore Brush Kit EN-47909

6.1.1.9 Injector Installer (to rail) EN-50791

6.1.1.10 Injector Rail Remover EN-49248

6.1.1.11 Injector Retaining Clip Installer EN-49247

6.1.1.12 Injector Retaining Clip Replacer EN-51097

6.1.1.13 Injector Seal Installer-sizer EN-48266

6.1.1.14 Injector Seal Installer-sizer EN-49245

6.1.1.15 Teflon Seal Sizer 303–1567

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