Fuel Pump Insulator Replacement (L87)

Engine Controls and Fuel - 5.3L L84 or 6.2L L87 | Repair Instructions | Document ID: 5739226 Single Use Fasteners and Components Intake Manifold Gasket [8x] Removal Procedure

Warning

Refer to Safety Glasses Warning.

Fuel Pump Insulator Replacement (L87) — figure 1

1. Air Cleaner Outlet Duct Bracket Bolt (1) » Remove
2. Remove engine wiring harness from air cleaner outlet duct bracket.

Fuel Pump Insulator Replacement (L87) — figure 2

3. Positive Crankcase Ventilation Fresh Air Tube (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
4. Air Cleaner Outlet Duct Clamp (2) » Loosen [2x]
5. Air Cleaner Outlet Duct (3) » Remove

Fuel Pump Insulator Replacement (L87) — figure 3

6. Plenum Front Panel Outer Reinforcement (1) » Remove — Plenum Front Panel Outer Reinforcement Removal and Installation

Fuel Pump Insulator Replacement (L87) — figure 4

7. Evaporative Emission Canister Purge Tube Connector (1) @ Evaporative Emission Canister Purge Solenoid Valve » Disengage — Plastic Collar Quick Connect Fitting Service
8. Evaporative Emission Canister Purge Tube (2) @ Evaporative Emission Canister Purge Solenoid Valve » Remove and position aside

Fuel Pump Insulator Replacement (L87) — figure 5

9. Engine Wiring Harness Connector (1) @ Throttle Body » Disconnect
10. Engine Wiring Harness Retainer (2) @ Intake Manifold Cover » Remove [2x]
11. Engine Wiring Harness Connector (3) @ Manifold Absolute Pressure Sensor » Disconnect
12. Engine Wiring Harness Connector (4) @ Evaporative Emission Canister Purge Solenoid Valve » Disconnect

Fuel Pump Insulator Replacement (L87) — figure 6

13. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Remove [4x]

Fuel Pump Insulator Replacement (L87) — figure 7

14. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Remove [3x]

Fuel Pump Insulator Replacement (L87) — figure 8

15. Positive Crankcase Ventilation Tube Connector (2) @ Intake Manifold » Disconnect and reposition — Plastic Collar Quick Connect Fitting Service

Fuel Pump Insulator Replacement (L87) — figure 9

Note

Some components not shown for graphic clarity.

16. Loosen the 10 intake manifold bolts (1) until the bolts are no longer threaded into the cylinder heads.
17. Move the intake manifold and intake manifold cover (2) forward enough to gain access to the rear engine wiring harness retainers.

Fuel Pump Insulator Replacement (L87) — figure 10

18. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Remove [4x]

Fuel Pump Insulator Replacement (L87) — figure 11

Note

The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness.

19. Remove the intake manifold and intake manifold cover (1) as an assembly.
20. Cover the cylinder head passages in order to prevent dirt or debris from entering the passages.

Fuel Pump Insulator Replacement (L87) — figure 12

21. Intake Manifold Gasket (1) » Remove and DISCARD [8x]

Fuel Pump Insulator Replacement (L87) — figure 13

Danger: 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. 22. Fuel Pump Insulator (1) » Remove Cleaning and Inspection Procedure - Conditional

Note

The following cleaning and inspection and/or overhaul steps are ONLY to be performed as determined necessary based on the condition of the part being removed with the intention of reinstallation. The labor time to perform any of these steps is not included in the base labor time and if required would need to be documented and submitted as Other Labor Hours for warranty claim reimbursement. A description of the repairs performed must be documented in the technician correction comments.

Fuel Pump Insulator Replacement (L87) — figure 14

1. Clean all sealing surfaces.
2. Dry the intake manifold with compressed air.
3. Inspect the intake manifold cylinder head deck for warpage.
4. Place a straight edge (1) across the intake manifold cylinder head deck surface.
5. Inspect the intake manifold for the following conditions: 5.1. Inspect for loose threaded inserts or studs. 5.2. Inspect for damaged or broken vacuum fitting. 5.3. Inspect the intake manifold assembly for cracks or other damage. 5.4. Inspect for damaged intake manifold gasket sealing surfaces.
6. Position the straight edge (1) across a minimum of two runner port openings and check for warpage using a feeler gage. Engine Mechanical Specifications
7. Inspect the ventilation system passages for restrictions. Installation Procedure

Danger: 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.  1. Fuel Pump Insulator (1) » Install

2. Intake Manifold Gasket (1) » Install NEW [8x]

3. Clean all sealing surfaces.

4. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 4.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 4.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 4.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 4.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

Note

The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness.

5. Position the intake manifold and Intake manifold cover (1) to install harness retainers.

6. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Install [4x]

7. Move the intake manifold and intake manifold cover (2) into place.

Note

Some components not shown for graphic clarity.

8. Intake Manifold Bolt (1) » Hand tighten [10x]

Caution

Refer to Fastener Caution.

9. Intake Manifold Bolt (1) » Tighten in sequence [10x] — Fastener Specifications

10. Positive Crankcase Ventilation Tube Connector (2) @ Intake Manifold » Install — Plastic Collar Quick Connect Fitting Service

11. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Install [3x]

12. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Install [4x]

13. Engine Wiring Harness Connector (4) @ Evaporative Emission Canister Purge Solenoid Valve » Connect

14. Engine Wiring Harness Connector (3) @ Manifold Absolute Pressure Sensor » Connect

15. Engine Wiring Harness Retainer (2) @ Intake Manifold Cover » Install [2x]

16. Engine Wiring Harness Connector (1) @ Throttle Body » Connect

17. Evaporative Emission Canister Purge Tube (2) @ Evaporative Emission Canister Purge Solenoid Valve » Install

18. Evaporative Emission Canister Purge Tube Connector (1) @ Evaporative Emission Canister Purge Solenoid Valve » Engage — Plastic Collar Quick Connect Fitting Service

19. Plenum Front Panel Outer Reinforcement (1) » Install — Plenum Front Panel Outer Reinforcement Removal and Installation

20. Air Cleaner Outlet Duct (3) » Install

21. Air Cleaner Outlet Duct Clamp (2) » Tighten [2x] — Fastener Specifications

22. Positive Crankcase Ventilation Fresh Air Tube (1) » Connect — Plastic Collar Quick Connect Fitting Service

23. Air Cleaner Outlet Duct Bracket Bolt (1) » Install and tighten — Fastener Specifications

24. Install engine wiring harness to air cleaner outlet duct bracket.