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Installation Procedure

WARNING: This page is about a different car, the 2009 Saturn Outlook, 2009 GMC Acadia, 2009 Chevrolet Traverse, and 2009 Buick Enclave. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: The camshaft must be in the base circle position before the high pressure fuel pump is installed.
  1. Use the EN-48896:  alignment gage to ensure that the camshaft lobe is in the base circle position. At base circle the tool will be flush with the head.
  2. Lubricate the high pressure fuel pump cylinder head bore and roller lifter with camshaft prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent.
  3. Install high pressure fuel pump roller lifter.
  4. Install a NEW high pressure fuel pump O-ring.
    5. Fig 1: Identifying High Pressure Fuel Pump & Components
    GM1977751Courtesy of GENERAL MOTORS CORP.
    NOTE: The high pressure fuel pump gasket has a retaining feature to hold the pump retaining bolts in place.
  5. Position the NEW high pressure fuel pump gasket (2) and bolts (4) to the fuel pump.
  6. Install the high pressure fuel pump (3) to the cylinder head (1). Force will be required while hand tightening the bolts.
    7. CAUTION: Refer to Fastener Caution .
  7. Tighten the high pressure fuel pump retaining bolts to 15 N.m (11 lb ft).
  8. Ensure the high pressure fuel pump and fuel rail fittings are clean prior to assembly.
  9. Install a NEW high pressure fuel pipe. Refer to Fuel Feed Intermediate Pipe Replacement (LLT) .
  10. Install the fuel feed pipe to the high pressure fuel pump. Refer to Fuel Feed Pipe Replacement (LLT) .
  11. Connect the high pressure fuel pump wiring harness.
  12. Install the fuel tank cap.
    13. NOTE: If a fuel leak accrues at the fuel rail, the fuel rail will need to be replaced.
  13. Inspect for leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2. Turn OFF the ignition, for 10 seconds.
    3. Turn ON the ignition, with the engine OFF.
    4. Inspect for fuel leaks.
  14. Install the pressure relief cap to the fuel feed pipe.
  15. Install the wiper module. Refer to Windshield Wiper Motor Replacement .
  16. Install the intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT .
  17. Install the high pressure fuel pump shield. Refer to Fuel Pipe Shield Replacement .
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