Fuel Rail Pressure Sensor Replacement (L84)

Engine Controls and Fuel - 5.3L L84 or 6.2L L87 | Repair Instructions | Document ID: 5694433 Single Use Fasteners and Components Intake Manifold Gasket [8x] Removal Procedure

Warning

Refer to Safety Glasses Warning.

1. Relieve the fuel system pressure. Fuel Pressure Relief

Fuel Rail Pressure Sensor Replacement (L84) — figure 1

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

Fuel Rail Pressure Sensor Replacement (L84) — figure 2

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

Fuel Rail Pressure Sensor Replacement (L84) — figure 3

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

Fuel Rail Pressure Sensor Replacement (L84) — figure 4

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

Fuel Rail Pressure Sensor Replacement (L84) — figure 5

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

Fuel Rail Pressure Sensor Replacement (L84) — figure 6

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

Fuel Rail Pressure Sensor Replacement (L84) — figure 7

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

Fuel Rail Pressure Sensor Replacement (L84) — figure 8

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

Fuel Rail Pressure Sensor Replacement (L84) — figure 9

Note

Some components not shown for graphic clarity.

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

Fuel Rail Pressure Sensor Replacement (L84) — figure 10

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

Fuel Rail Pressure Sensor Replacement (L84) — 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.

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

Fuel Rail Pressure Sensor Replacement (L84) — figure 12

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

Fuel Rail Pressure Sensor Replacement (L84) — 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. 23. Fuel Pump Insulator (1) » Remove

Fuel Rail Pressure Sensor Replacement (L84) — figure 14

Caution

Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution.

Caution

To tighten or loosen the fuel injection fuel rail fuel pressure sensor, apply force ONLY to the attached hexagon. Applying force to the plastic housing of the sensor may damage the sensor.

24. Electrical Connector (1) @ Fuel Rail Pressure Sensor (2) » Disconnect

Note

Some fuel may leak from the fuel rail pressure sensor orifice after the sensor is removed. Dry the area around this orifice after the removal of the sensor using a lint free cloth and inspect the fuel rail pressure sensor sealing surface. The surface should be free of fuel, debris, and burrs.

25. Fuel Rail Pressure Sensor (2) @ Fuel Injection Fuel Rail (3) » 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 Rail Pressure Sensor Replacement (L84) — figure 15

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

Caution

To tighten or loosen the fuel injection fuel rail fuel pressure sensor, apply force ONLY to the attached hexagon. Applying force to the plastic housing of the sensor may damage the sensor.

Note

Ensure the fuel rail threads are clean and free of any excess fuel, or the fuel rail pressure sensor will NOT seal properly.

1. Lubricate the threads and sealing surface of the fuel rail pressure sensor with one drop of clean engine oil.
2. Install the fuel rail pressure sensor (2) and hand tighten.
3. Remove the fuel rail pressure sensor (2) from the fuel injection fuel rail (3) and re-lubricate with one drop of clean engine oil.

Caution

Refer to Component Fastener Tightening Caution.

4. Fuel Rail Pressure Sensor (2) @ Fuel Injection Fuel Rail (3) » Install and tighten — Fastener Specifications
5. Electrical Connector (1) @ Fuel Rail Pressure Sensor (2) » Connect

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.  6. Fuel Pump Insulator (1) » Install

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

8. Remove the covers from the cylinder head passages.

9. Clean all sealing surfaces.

10. 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: 10.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 10.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 10.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 10.4. 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.

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

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

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

Note

Some components not shown for graphic clarity.

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

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

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

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

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

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

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

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

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

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

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

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

26. Air Cleaner Outlet Duct (3) » Install

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

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

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

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

31. Pressurize the fuel system and inspect for leaks.

32. Inspect for fuel leaks.