Engine Controls/fuel - 3.0L - Repair Instructions: Removal & Installation Chevrolet Captiva I facelift

Fuel Pressure Gauge Installation and Removal

Special Tools

CH 48027 Digital Pressure Gauge

For equivalent regional tools, refer to Special Tools (Diagnostic Tools)

Installation Procedure

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief»(ref-490251-S32096861152012072700000) .
2. Connect the CH 48027 gauge (1) to the CH 48027 adapter (2).
3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH 48027 gauge (1), refer to the manufacture's directions.

Removal Procedure

1. Relieve the fuel system pressure, if required. Perform the following steps: Wrap a shop towel around the fuel rail service port. Place the hose on the CH 48027 adapter (2) into an approved gasoline container. Open the valve on the CH 48027 adapter (2) in order to bleed any fuel from the fuel rail. Close the valve on the CH 48027 adapter (2). Remove the hose on the CH 48027 adapter (2) from the approved gasoline container. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
2. Disconnect the CH 48027 gauge (1) from the CH 48027 gauge (2).
3. Disconnect the CH 48027 adapter (2) from the CH 48027 adapter (3).
4. Disconnect the CH 48027 adapter (3) from the fuel rail service port.
5. Install the fuel rail service port cap.
6. Install the engine cover, if required.
7. Tighten the fuel fill cap.

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief»(ref-490251-S32096861152012072700000) .
2. Remove the retainer from the quick-connect fitting.
3. Blow dirt out of the fitting using compressed air.
4. Depending on the fuel line size and ability to access the fitting, choose the appropriate tool: CH-41769 fuel line disconnect tool set or CH-44581 fuel line disconnect tool. Insert the CH-41769 fuel line disconnect tool set or CH-44581 fuel line disconnect tool into the female connector, then push inward to release the locking tabs.
5. Pull the connection apart.
6. Using a clean shop towel, wipe off the male pipe end.
7. Inspect both ends of the fitting for dirt and burrs.
8. Clean or replace the components as required.

1. Apply a few drops of clean engine oil to the male pipe end.
2. Push both sides of the quick-connect fitting together to cause the retaining tabs to snap into place.
3. Pull on both sides of the quick-connect fitting to make sure the connection is secure.
4. Install the retainer to the quick-connect fitting.
5. Inspect for leaks using the following procedure: Turn the ignition ON, with the engine OFF for 2 seconds. Turn the ignition OFF, for 10 seconds. Turn the ignition ON, with the engine OFF for 2 seconds. Turn the ignition OFF. Inspect for leaks.

1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the «Fuel Pressure Relief»(ref-490251-S32096861152012072700000) .
2. Using compressed air, blow any dirt out of the quick-connect fitting.
3. This step applies to Bartholomew style connectors ONLY. Squeeze the plastic quick-connect fitting release tabs.
4. This step applies to Q Release style connectors ONLY. Release the fitting by Pushing the tab toward the other side of the slot in the fitting.
5. This step applies to Squeeze to Release style connectors ONLY. Squeeze where indicated by arrows on both sides of the plastic ring surrounding the quick-connect fitting.
6. This step applies to Squeeze to Release style connectors ONLY. Push in the male side slightly in order to slide the retainer away from the retainers, squeeze where indicated by arrows on both sides of the plastic ring surrounding the quick-connect fitting.
7. This step applies to Sliding Retainer style connectors ONLY. Release the fitting by pressing on one side of the release tab causing it to push in slightly. If the tab doesn't move try pressing the tab in from the opposite side. The tab will only move in one direction.
8. This step applies to the Global Connector style only. Push the connector toward the tube in order to release the pressure. Press and hold down the release mechanism, and pull the connector straight out.
9. This step applies to the TI Loc style only. Push the connector toward the tube in order to release the pressure. Release the redundant latch (1) with two fingers or a flat bladed tool. Then press and hold down the bottom release mechanism (2) and pull the connector straight out.
10. This step applies to the Safe Lock style only. Push the connector toward the tube in order to release the pressure. Release the second latch (1) with two fingers. Then press and hold down the bottom release mechanism (2) and pull the connector straight out.
11. Using a clean shop towel, wipe off the male pipe end.
12. Inspect both ends of the fitting for dirt and burrs.
13. Clean or replace components as necessary.

1. Apply a few drops of clean engine oil to the male pipe end.
2. Push both sides of the quick-connect fitting together in order to cause the retaining feature to snap into place.
3. Pull on both sides of the quick-connect fitting to make sure the connection is secure.
4. Insert the tube in the connector until the retainer snaps in place.
5. Push down on the redundant latch (1) until it is fully engaged and snapped into position.
6. Insert the tube in the connector until the retainer snaps in place.
7. Push down on the second latch (1) in order to secure the connection.
8. Inspect for leaks using the following procedure: Turn the ignition ON, with the engine OFF for 2 seconds. Turn the ignition OFF, for 10 seconds. Turn the ignition ON, with the engine OFF for 2 seconds. Turn the ignition OFF. Inspect for leaks.

Scheme 26

Fuel Filter Replacement

1. Ensure that the fuel level in the tank is less than 1/4 full. If necessary, drain the fuel tank to at least this level. Refer to «Fuel Tank Draining»(ref-490251-S19282939382012072700000) .
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief»(ref-490251-S32096861152012072700000) .
3. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-490217-S20127220552012072700000) .
4. Raise and support the vehicle . Refer to «Lifting and Jacking the Vehicle»(ref-490192-S40791490082012072700000) .
5. Remove the exhaust system. Refer to «Exhaust Muffler Replacement (N10-Left Side)»(ref-490237-S21539164932012072700000) , «Exhaust Muffler Replacement (NB5)»(ref-490237-S08518657892012072700000) , «Exhaust Muffler Replacement (N10-Right Side)»(ref-490237-S27490533852012072700000) .
6. Remove the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-490238-S17114612372012072700000) .
7. Place a suitable container under the fuel line connection in order to catch any dripping fuel.
8. Remove the evaporative emission canister. Refer to «Evaporative Emission Canister Replacement»(ref-490251-S29203077962012072700000) .
9. Disconnect the chassis fuel supply line (2) from the fuel tank.
10. Disconnect the fuel filler tube, EVAP vent hose, and fresh air hose from the fuel tank.
11. Disconnect the fuel tank electrical connector and remove the electrical connector retainer from the rear frame.
12. Using a suitable adjustable jack, support the fuel tank.
13. Remove the fuel tank strap nuts and lower the fuel tank straps.
14. Lower the front of the fuel tank (with shield), and pull the tank forward to clear the rear drive module.
15. If replacing the fuel tank, remove the fuel tank module assemblies. Refer to «Fuel Tank Fuel Pump Module Replacement»(ref-490251-S11865631632012072700000) , and «Fuel Tank Fuel Pump Module Replacement - Secondary»(ref-490251-S28352406342012072700000) .
16. If replacing the fuel tank, remove the heat shield, hoses and wiring harness and transfer to the new tank.

1. If previously removed, install the fuel tank module assemblies. Refer to «Fuel Tank Fuel Pump Module Replacement»(ref-490251-S11865631632012072700000) , and «Fuel Tank Fuel Pump Module Replacement - Secondary»(ref-490251-S28352406342012072700000) .
2. Using a suitable adjustable jack, install the fuel tank heat shield and fuel tank assembly to the vehicle.
3. Install the fuel tank straps and the fuel tank strap-to-body nuts and tighten to 20 N.m (15 lb ft).
4. Connect the fuel tank electrical connector and install the electrical connector retainer to the rear frame.
5. Connect the EVAP vent, and fresh air hoses to the fuel tank.
6. Connect the fuel filler tube to the fuel tank. Tighten the fuel filler tube clamp to 5 N.m (44 lb in).
7. Connect the chassis fuel supply line (2) to the fuel tank.
8. Install the evaporative emission canister. Refer to «Evaporative Emission Canister Replacement»(ref-490251-S29203077962012072700000) .
9. Install the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-490238-S17114612372012072700000) .
10. Install the exhaust system. Refer to «Exhaust Muffler Replacement (N10-Left Side)»(ref-490237-S21539164932012072700000) , «Exhaust Muffler Replacement (NB5)»(ref-490237-S08518657892012072700000) , «Exhaust Muffler Replacement (N10-Right Side)»(ref-490237-S27490533852012072700000) .
11. Lower the vehicle .
12. Fill the fuel tank with gasoline.
13. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-490217-S20127220552012072700000) .
14. Prime the fuel system: Cycle the ignition ON for 5 seconds and then OFF for 10 seconds. Repeat the previous step twice. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds. If the engine does not start, repeat steps 14.1-14.3.

1. Ensure that the fuel level in the tank is less than 1/4 full. If necessary, drain the fuel tank to at least this level. Refer to «Fuel Tank Draining»(ref-490251-S19282939382012072700000) .
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief»(ref-490251-S32096861152012072700000) .
3. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-490217-S20127220552012072700000) .
4. Raise and support the vehicle . Refer to «Lifting and Jacking the Vehicle»(ref-490192-S40791490082012072700000) .
5. Remove the exhaust system. Refer to «Exhaust Muffler Replacement (N10-Left Side)»(ref-490237-S21539164932012072700000) , «Exhaust Muffler Replacement (NB5)»(ref-490237-S08518657892012072700000) , «Exhaust Muffler Replacement (N10-Right Side)»(ref-490237-S27490533852012072700000) .
6. Disconnect the canister vent valve electrical connectors.
7. Disconnect the vent hose from the canister filter.
8. Disconnect the fuel tank vent pipe from the evaporative emission canister.
9. Disconnect the chassis fuel supply line (2) from the fuel tank.
10. Disconnect the fuel filler tube, EVAP vent hose, and fresh air hose from the fuel tank.
11. Disconnect the fuel tank electrical connector and remove the electrical connector retainer from the rear frame.
12. Support the fuel tank using a suitable jack.
13. Remove the fuel tank strap nuts, and lower the fuel tank straps.
14. Lower the fuel tank from the underbody of the vehicle.
15. If replacing the fuel tank, remove the fuel tank module assemblies. Refer to «Fuel Tank Fuel Pump Module Replacement»(ref-490251-S11865631632012072700000) , and «Fuel Tank Fuel Pump Module Replacement - Secondary»(ref-490251-S28352406342012072700000) .
16. If replacing the fuel tank, remove the heat shield, hoses and wiring harness, and transfer to the new tank.

1. If previously removed, install the fuel tank module assemblies. Refer to «Fuel Tank Fuel Pump Module Replacement»(ref-490251-S11865631632012072700000) , and «Fuel Tank Fuel Pump Module Replacement - Secondary»(ref-490251-S28352406342012072700000) .
2. Using an adjustable jack, slowly raise and reposition the fuel tank (3) in order to install the tank to the vehicle.
3. Install the fuel tank straps and the fuel tank strap-to-body nuts and tighten to 20 N.m (15 lb ft).
4. Connect the fuel tank electrical connector and install the electrical connector retainer to the rear frame.
5. Connect the EVAP vent, and fresh air hoses to the fuel tank.
6. Connect the fuel filler tube to the fuel tank. Tighten the fuel filler tube clamp to 5 N.m (44 lb in).
7. Connect the chassis fuel supply line (2) to the fuel tank.
8. Connect the fuel tank vent pipe to the evaporative emission canister.
9. Connect the vent hose to the canister filter.
10. Connect the canister vent valve electrical connector.
11. Install the exhaust system. Refer to «Exhaust Muffler Replacement (N10-Left Side)»(ref-490237-S21539164932012072700000) , «Exhaust Muffler Replacement (NB5)»(ref-490237-S08518657892012072700000) , «Exhaust Muffler Replacement (N10-Right Side)»(ref-490237-S27490533852012072700000) .
12. Lower the vehicle .
13. Fill the fuel tank with gasoline.
14. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-490217-S20127220552012072700000) .
15. Prime the fuel system: Cycle the ignition ON for 5 seconds and then OFF for 10 seconds. Repeat the previous step twice. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds. If the engine does not start, repeat steps 15.1-15.3.

Fuel Tank Fuel Pump Module Replacement

Special Tools

J-45722 Fuel Tank Sender Wrench

For equivalent regional tools, refer to Special Tools (Diagnostic Tools) .

1. Remove the fuel tank. Refer to «Fuel Tank Replacement (FWD)»(ref-490251-S40036638722012072700000) , «Fuel Tank Replacement (AWD)»(ref-490251-S18675518572012072700000) .
2. Disconnect the crossover tube from the secondary fuel pump module. Refer to «Fuel Tank Fuel Pump Module Replacement - Secondary»(ref-490251-S28352406342012072700000) .
3. Disconnect the electrical connectors (1).
4. Disconnect the fuel and evaporative emission lines (2). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-490251-S01171973742012072700000) .
5. Using the J-45722 wrench , remove the cam lock ring (1) by turning counterclockwise.
6. Remove the primary fuel tank module (1) and the O-ring (2).
7. If replacing the fuel pump module only, remove the primary fuel level sensor. Refer to «Primary Fuel Level Sensor Replacement»(ref-490251-S27019846102012072700000) .

1. If replacing the fuel pump module only, install the primary fuel level sensor. Refer to «Primary Fuel Level Sensor Replacement»(ref-490251-S27019846102012072700000) .
2. Install a NEW O-ring (2) and the primary fuel tank module (1).
3. Using the J-45722 wrench , install the cam lock ring (1) by turning clockwise.
4. Connect the electrical connectors (1).
5. Connect the fuel and evaporative emission lines (2). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-490251-S01171973742012072700000) .
6. Connect the crossover tube to the secondary fuel pump module. Refer to «Fuel Tank Fuel Pump Module Replacement - Secondary»(ref-490251-S28352406342012072700000) .
7. Install the fuel tank. Refer to «Fuel Tank Replacement (FWD)»(ref-490251-S40036638722012072700000) , «Fuel Tank Replacement (AWD)»(ref-490251-S18675518572012072700000) .

Fuel Tank Fuel Pump Module Replacement - Secondary

Special Tools

CH-48482 Fuel Tank Sender Wrench

For equivalent region tools, refer to Special Tools (Diagnostic Tools) .

1. Remove the fuel tank. Refer to «Fuel Tank Replacement (FWD)»(ref-490251-S40036638722012072700000) , «Fuel Tank Replacement (AWD)»(ref-490251-S18675518572012072700000) .
2. Disconnect the electrical connector (1).
3. Disconnect the evaporative emission line (2). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-490251-S01171973742012072700000) .
4. Using the CH-48482 wrench , remove the cam lock ring (1) by turning counterclockwise.
5. Partially raise the secondary fuel pump module and disconnect the crossover tube (1) by squeezing the plastic retaining tabs (2).
6. Remove the secondary fuel tank module (1) and the O-ring (2).

1. Partially install the secondary fuel pump module and connect the crossover tube (1) by sliding into position.
2. Install a NEW O-ring (2) and the secondary fuel tank module (1).
3. Using the CH-48482 wrench , install the cam lock ring (1) by turning clockwise.
4. Connect the electrical connector (1).
5. Connect the evaporative emission line (2). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-490251-S01171973742012072700000) .
6. Install the fuel tank. Refer to «Fuel Tank Replacement (FWD)»(ref-490251-S40036638722012072700000) , «Fuel Tank Replacement (AWD)»(ref-490251-S18675518572012072700000) .

Scheme 27

Fuel Pump Flow Control Module Replacement

Scheme 28

Fuel Tank Pressure Sensor Replacement

Scheme 29

Fuel Tank Filler Pipe Replacement

Scheme 30

Primary Fuel Level Sensor Replacement

Scheme 31

Fuel Line Replacement - Chassis

Scheme 32

Fuel Pressure Sensor Replacement - Fuel Feed Pipe

Scheme 33

Fuel Feed Pipe Replacement (LF1 or LFW)

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (LF1, LFW)

Special Tools

EN-49248 Injector Rail Assembly Remover

For equivalent regional tools, refer to Special Tools (Diagnostic Tools) .

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief»(ref-490251-S32096861152012072700000) .
2. Remove the fuel pipe shield. Refer to «Fuel Pipe Shield Replacement (LF1 or LFW)»(ref-490251-S15803733072012072700000) .
3. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-490236-S17329104722012072700000) .
4. Remove the fuel feed intermediate pipe. Refer to «Fuel Feed Intermediate Pipe Replacement (LF1 or LFW)»(ref-490251-S32143419282012072700000) .
5. Remove the foam insulator from the fuel rails.
6. Cut the plastic tie strap (1)
7. Disconnect the fuel pressure sensor electrical connector (2).
8. Remove the fuel pressure sensor (3).
9. Remove the bank 2 fuel rail fasteners (1).
10. Remove the bank 1 fuel rail fasteners (1) for clearance purposes.
11. Using the EN-49248-4 hook , raise the fuel rail (1) as an assembly.
12. Once the fuel rail is free, remove the EN-49248 special tool.
13. Slide the fuel rail (1) toward the front of the engine approximately 1 inch (25.4 mm), in order to clear the center injector bore.
14. Disconnect the bank 2 fuel injector and fuel pressure sensor electrical connections.
15. Once the fuel rail is removed, clean and inspect the fuel injectors. Refer to «Fuel Rail and Injectors Cleaning and Inspection»(ref-490292-S03168698222012072700000) .

1. Slide the fuel rail (1) toward the rear of the engine approximately 1 inch (25.4 mm), in order to align the center injector bore.
2. Hand tighten the two outer fuel rail fasteners to seat the injectors.
3. Start and hand tighten the remaining fuel rail fasteners.
4. Tighten the fuel rail fasteners in the sequence shown above: First pass 12 N.m (106 lb in). Final pass 23 N.m (17 lb ft).
5. Tighten the fuel pressure sensor (3) to 33 (25 lb ft)
6. Connect the fuel pressure sensor electrical connector (2) and secure it with a new plastic zip tie.
7. Connect the bank 1 fuel injector electrical connections.
8. Install the fuel feed intermediate pipe. Refer to «Fuel Feed Intermediate Pipe Replacement (LF1 or LFW)»(ref-490251-S32143419282012072700000) .
9. 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.
10. Install the foam insulator to the fuel rails.
11. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-490236-S17329104722012072700000) .
12. Install the fuel pipe shield. Refer to «Fuel Pipe Shield Replacement (LF1 or LFW)»(ref-490251-S15803733072012072700000) .
13. Install the low side fuel pressure service port cap.
14. Install the fuel tank cap.

Fuel Injection Fuel Rail Assembly Replacement - Bank 2 (LF1, LFW)

Special Tools

EN-49248 Injector Rail Assembly Remover

For equivalent regional tools, refer to Special Tools (Diagnostic Tools) .

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief»(ref-490251-S32096861152012072700000) .
2. Remove the fuel pipe shield. Refer to «Fuel Pipe Shield Replacement (LF1 or LFW)»(ref-490251-S15803733072012072700000) .
3. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-490236-S17329104722012072700000) .
4. Remove the fuel feed intermediate pipe. Refer to «Fuel Feed Intermediate Pipe Replacement (LF1 or LFW)»(ref-490251-S32143419282012072700000) .
5. Remove the foam insulator from the fuel rails.
6. Cut the plastic tie strap (1).
7. Disconnect the fuel pressure sensor electrical connector (2).
8. Remove the fuel pressure sensor (3).
9. Remove the bank 2 fuel rail fasteners (1).
10. Remove the bank 1 fuel rail fasteners (1) for clearance purposes.
11. Using the EN-49248-4 hook , raise the fuel rail (1) as an assembly.
12. Once the fuel rail is free, remove the EN-49248 special tool.
13. Slide the fuel rail (1) toward the front of the engine approximately 1 inch (25.4 mm), in order to clear the center injector bore.
14. Disconnect the bank 2 fuel injector and fuel pressure sensor electrical connections.
15. Once the fuel rail is removed, remove the injectors to clean and inspect. Refer to «Fuel Rail and Injectors Cleaning and Inspection»(ref-490292-S03168698222012072700000) .

1. Slide the fuel rail (1) toward the rear of the engine approximately 1 inch (25.4 mm), in order to align the center injector bore.
2. Hand tighten the two outer fuel rail fasteners to seat the injectors.
3. Start and hand tighten the remaining fuel rail fasteners.
4. Tighten the fuel rail fasteners in the sequence shown above: First pass 12 N.m (106 lb in). Final pass 23 N.m (17 lb ft).
5. Tighten the fuel pressure sensor (3) to 33 (25 lb ft).
6. Connect the fuel pressure sensor electrical connector (2) and secure it with a new plastic zip tie.
7. Connect the bank 1 fuel injector electrical connections
8. Install the fuel feed intermediate pipe. Refer to «Fuel Feed Intermediate Pipe Replacement (LF1 or LFW)»(ref-490251-S32143419282012072700000) .
9. 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.
10. Install the foam insulator to the fuel rails.
11. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-490236-S17329104722012072700000) .
12. Install the fuel pipe shield. Refer to «Fuel Pipe Shield Replacement (LF1 or LFW)»(ref-490251-S15803733072012072700000) .
13. Install the low side fuel pressure service port cap.
14. Install the fuel tank cap.

Scheme 34

Fuel Feed Intermediate Pipe Replacement (LF1 or LFW)

Scheme 35

Fuel Pipe Shield Replacement (LF1 or LFW)

Fuel Pump Replacement

Special Tools

EN-48896 High Pressure Fuel Pump Installation Alignment Gauge

For equivalent regional tools, refer to Special Tools (Diagnostic Tools) .

1. Relieve the low and high side fuel system pressure. Refer to «Fuel Pressure Relief»(ref-490251-S32096861152012072700000) .
2. Remove the high pressure fuel pump shield. Refer to «Fuel Pipe Shield Replacement (LF1 or LFW)»(ref-490251-S15803733072012072700000) .
3. Disconnect the engine wiring harness electrical connector from the high pressure fuel pump.
4. Remove the low pressure feed pipe. Refer to «Fuel Feed Pipe Replacement (LF1 or LFW)»(ref-490251-S36371148172012072700000) .
5. Remove the high pressure pipe. Discard the pipe. Refer to «Fuel Feed Intermediate Pipe Replacement (LF1 or LFW)»(ref-490251-S32143419282012072700000) .
6. Remove and discard the high pressure fuel pump bolts (1).
7. Remove the high pressure fuel pump (2).
8. Remove and discard the high pressure fuel pump O-ring (3).
9. Remove and discard the high pressure fuel pump gasket (4).
10. Remove the high pressure fuel pump roller lifter (5).

1. Use the EN-48896 alignment gauge 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. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-490287-S06581861002012072700000) .
3. Install the high pressure fuel pump roller lifter (5).
4. Install a NEW high pressure fuel pump O-ring (3).
5. Position the NEW high pressure fuel pump gasket (4) and bolts (1) to the fuel pump.
6. Install the high pressure fuel pump (2). Force will be required while hand tightening the bolts.
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 (LF1 or LFW)»(ref-490251-S32143419282012072700000) .
10. Install the fuel feed pipe to the high pressure fuel pump. Refer to «Fuel Feed Pipe Replacement (LF1 or LFW)»(ref-490251-S36371148172012072700000) .
11. Connect the high pressure fuel pump wiring harness.
12. Install the fuel tank cap.
13. Inspect for 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.
14. Install the pressure relief cap to the fuel feed pipe.
15. Install the high pressure fuel pump shield. Refer to «Fuel Pipe Shield Replacement (LF1 or LFW)»(ref-490251-S15803733072012072700000) .

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief»(ref-490251-S32096861152012072700000) .
2. Remove the fuel pipe shield. Refer to «Fuel Pipe Shield Replacement (LF1 or LFW)»(ref-490251-S15803733072012072700000) .
3. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-490236-S17329104722012072700000) .
4. Remove the fuel feed intermediate pipe. Refer to «Fuel Feed Intermediate Pipe Replacement (LF1 or LFW)»(ref-490251-S32143419282012072700000) .
5. Remove the foam insulator from the fuel rails.
6. Remove the cylinder head. Refer to «Cylinder Head Replacement - Left Side»(ref-490236-S36192382552012072700000) , or «Cylinder Head Replacement - Right Side»(ref-490236-S00966355322012072700000)
7. Remove the bolts (1) from the bank 2 fuel rail.
8. Remove the bank 1 fuel rail and injectors (2) as an assembly. Refer to «Cylinder Head Disassemble (LF1, LFW or LFX)»(ref-490292-S08680681352012072700000) .
9. Disconnect the bank 1 fuel injector electrical connections.
10. Using the EN-49248-4 hook , raise the fuel rail (1) as an assembly.
11. Once the fuel rail is free, remove the EN-49248 special tool.
12. If the bank 2 fuel rail or injectors are being serviced, remove them. Refer to «Cylinder Head Disassemble (LF1, LFW or LFX)»(ref-490292-S08680681352012072700000) .
13. Disconnect the bank 2 fuel injector and fuel pressure sensor electrical connections.
14. It is necessary to rebuild the fuel injectors. Refer to «Fuel Rail and Injectors Cleaning and Inspection»(ref-490292-S03168698222012072700000) .

1. Clean the fuel injector bores using EN-47909 kit.
2. Ensure that the fuel injectors have been properly rebuilt and lubricated. Refer to «Fuel Rail and Injectors Cleaning and Inspection»(ref-490292-S03168698222012072700000) .
3. Connect the bank 2 fuel injector and fuel pressure sensor electrical connections.
4. Position the bank 2 fuel rail and evenly hand tighten the 2 outer fuel rail bolts to seat the injectors into the injector bores. Remove the bolts.
5. Connect the bank 1 fuel injector electrical connections.
6. Position the bank 1 fuel rail and evenly hand tighten the 2 outer fuel rail bolts to seat the injectors into the injector bores.
7. Start and hand tighten the remaining fuel rail bolts.
8. Tighten the bank 1 and bank 2 fuel rail bolts to 25 (18 lb ft).
9. Replace any wire harness tie straps cut from the fuel rails.
10. Install the cylinder head. Refer to «Cylinder Head Replacement - Left Side»(ref-490236-S36192382552012072700000) , or «Cylinder Head Replacement - Right Side»(ref-490236-S00966355322012072700000)
11. Install the fuel feed intermediate pipe. Refer to «Fuel Feed Intermediate Pipe Replacement (LF1 or LFW)»(ref-490251-S32143419282012072700000) .
12. 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.
13. Install the foam insulator to the fuel rails.
14. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-490236-S17329104722012072700000) .
15. Install the fuel pipe shield. Refer to «Fuel Pipe Shield Replacement (LF1 or LFW)»(ref-490251-S15803733072012072700000) .
16. Install the low side fuel pressure service port cap.

Scheme 36

Evaporative Emission Canister Purge Solenoid Valve Replacement (LF1 or LFW)

1. Remove the evaporative emission (EVAP) canister. Refer to «Evaporative Emission Canister Replacement»(ref-490251-S29203077962012072700000) .
2. Rotate the EVAP canister vent valve counterclockwise to release from the locked position.
3. Remove the vent valve from the EVAP canister.

1. Insert the EVAP canister vent solenoid valve into the EVAP canister, with the valve aligned to the released position.
2. Rotate vent valve clockwise to secure into the locked position.
3. Install the EVAP canister. Refer to «Evaporative Emission Canister Replacement»(ref-490251-S29203077962012072700000) .

Scheme 37

Evaporative Emission Line Replacement - Chassis to Canister

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-490192-S40791490082012072700000) .
2. Disconnect the EVAP canister fresh air hose/pipe from the fuel tank fresh air hose/pipe (2). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-490251-S01171973742012072700000) .
3. Disconnect the EVAP canister vent hose/pipe from the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-490251-S01171973742012072700000) .
4. Disconnect the EVAP canister purge hose/pipe (1) from the EVAP canister.
5. Remove the EVAP canister-to-underbody nuts (3).
6. Lower the EVAP canister.
7. Disconnect the EVAP vent solenoid electrical connector (1).
8. Remove the EVAP canister (4) from the vehicle.

1. Connect the EVAP vent solenoid electrical connector (1).
2. Install the EVAP canister (4) to the underbody of the vehicle.
3. Install the EVAP canister-to-underbody nuts (3). Tighten Tighten the nuts to 9 N.m (80 lb in).
4. Connect the EVAP canister purge hose/pipe (1) to the EVAP canister.
5. Connect the EVAP canister vent hose/pipe (3) to the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-490251-S01171973742012072700000) .
6. Connect the EVAP canister fresh air hose/pipe to the fuel tank fresh air hose/pipe (2). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-490251-S01171973742012072700000) .
7. Lower the vehicle.

1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-490236-S17329104722012072700000) .
2. Disconnect the engine wiring harness electrical connector(s) (1) from the ignition coil(s) (4).
3. Remove the ignition coil bolt(s).
4. Remove the ignition coil(s).

1. Install the ignition coil(s).
2. Install the ignition coil bolt(s). Tighten Tighten the bolt(s) to 10 N.m (89 lb in).
3. Connect the engine wiring harness electrical connector(s) (1) to the ignition coil(s) (4).
4. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-490236-S17329104722012072700000) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-490236-S40140960612012072700000) .
2. Disconnect the engine wiring harness electrical connector(s) (5) from the ignition coil(s) (4).
3. Remove the ignition coil bolt(s).
4. Remove the ignition coil(s).

1. Install the ignition coil(s).
2. Install the ignition coil bolt(s). Tighten Tighten the bolt(s) to 10 N.m (89 lb in).
3. Connect the engine wiring harness electrical connector(s) (5) to the ignition coil(s) (4).
4. Install theintake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-490236-S40140960612012072700000) .

1. Remove the ignition coil(s). Refer to «Ignition Coil Replacement - Bank 1»(ref-490251-S07398816482012072700000) , and/or «Ignition Coil Replacement - Bank 2»(ref-490251-S28134242322012072700000) .
2. Use compressed air in order to remove debris from the spark plug cavity.
3. Remove the spark plug.

1. Ensure that the spark plug gap is equivalent to the spark plug gap specification. Refer to «Ignition System Specifications»(ref-490287-S38162525182012072700000) .
2. Install the spark plug and tighten to 18 N.m (13 lb ft)..
3. Install the ignition coil(s). Refer to «Ignition Coil Replacement - Bank 1»(ref-490251-S07398816482012072700000) , and/or «Ignition Coil Replacement - Bank 2»(ref-490251-S28134242322012072700000) .

Scheme 38

Crankshaft Position Sensor Replacement

Scheme 39

Camshaft Position Sensor Replacement - Bank 2 (Left Side) Exhaust

Scheme 40

Camshaft Position Sensor Replacement - Bank 2 (Left Side) Intake

Scheme 41

Camshaft Position Sensor Replacement - Bank 1 (Right Side) Exhaust

Scheme 42

Camshaft Position Sensor Replacement - Bank 1 (Right Side) Intake

Scheme 43

Camshaft Position Actuator Solenoid Valve Solenoid Replacement - Bank 1 (Right Side) Intake

Scheme 44

Camshaft Position Actuator Solenoid Valve Solenoid Replacement - Bank 1 (Right Side) Exhaust

Scheme 45

Camshaft Position Actuator Solenoid Valve Solenoid Replacement - Bank 2 (Left Side) Intake

Scheme 46

Camshaft Position Actuator Solenoid Valve Solenoid Replacement - Bank 2 (Left Side) Exhaust

Scheme 47

Knock Sensor Replacement - Bank 1

Scheme 48

Knock Sensor Replacement - Bank 2

Scheme 49

Air Cleaner Element Replacement

Scheme 50

Air Cleaner Assembly Replacement

1. Remove the front bumper fascia. Refer to «Front Bumper Fascia Replacement (Base)»(ref-490208-S00530710952012072700000) .
2. Remove the air cleaner inlet duct bolts (1).
3. Pull on and dislocate the air cleaner inlet duct (1) from the air cleaner assembly and vehicle body grommet.

1. Position the air cleaner inlet duct (1) in the vehicle body grommet and air cleaner assembly.
2. Install the air cleaner inlet duct bolts (1). Tighten Tighten the bolts to 6 N.m (53 lb in).
3. Install the front bumper fascia. Refer to «Front Bumper Fascia Replacement (Base)»(ref-490208-S00530710952012072700000) .

Scheme 51

Air Cleaner Outlet Duct Replacement