GM Service Manual Online
For 1990-2009 cars only
  1. Turn the carnkshaft to align number 1 cylinder Top Dead Center (TDC) mark to pointer.
  2. Turn the coupling of the supply pump to align the timing mark on the supply pump and the pointer on the air compressor body.
  3. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  4. Install the supply pump assembly onto the pump bracket.
  5. Tighten
    Tighten the supply pump fixing bolts to 25 N·m (18 lb ft).

  6. Install the coupling bolts.
  7. Tighten
    Tighten the coupling bolts to the following:

    4.1. Bolt 1: 91 N·m (66 lb ft)
    4.2. Bolt 2: 61 N·m (46 lb ft)
    4.3. Bolt 1: 60 N·m (45 lb ft)
  8. Install the two fuel supply pipes between the supply pump and the common rail.
  9. Install the oil return pipe.
  10. Install the oil feed pipe.
  11. Install the the fuel return pipe.
  12. Important: When installing the fuel feed pipe on the fuel feed pump, you must use a special gasket between the feed pipe eye (on the relief valve) and the return pipe eye (short return pipe). If you use any other gasket it will cause the engine to not start.

  13. Install the fuel feed pipe.
  14. Tighten
    Tighten the clamp bolts to 6 N·m (52 lb in).

  15. Connect the Pump Position (G) sensor harness connector.