Valve Rocker Arm Oil Control Valve Harness Replacement (L87)

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) Single Use Fasteners and Components Engine Block Valley Cover Gasket Fuel Feed Intermediate Pipe [2x] Fuel Injector Nozzle Housing Seal [8x] Fuel Injector Seal [4x] Fuel Pump Bracket Gasket Intake Manifold Gasket [8x] Wiring Harness Connector Seal Special Tools Engine Controls and Fuel - 5.3L (L84) or 6.2L (L87) EN-49248 Injector Rail Assembly Remover EN-51092 Fuel Pump Installation Gauge EN-51955 Fuel Injector Seal Install/Sizer Equivalent regional tools: Special Tools Removal Procedure

1. Relieve the fuel system pressure. Fuel Pressure Relief

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 1

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

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — 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

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 3

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

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — 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

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — 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

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 6

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

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 7

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

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 8

16. Positive Crankcase Ventilation Tube Connector (1) @ Intake Manifold » Disconnect and reposition — Plastic Collar Quick Connect Fitting Service

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — 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.

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 10

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

Valve Rocker Arm Oil Control Valve Harness 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.

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.

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 12

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

Valve Rocker Arm Oil Control Valve Harness 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.

Warning

Refer to Safety Glasses Warning.

23. Fuel Pump Insulator (1) » Remove

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 14

24. Fuel Feed Pipe (1) » Disconnect — Metal Collar Quick Connect Fitting Service
25. Fuel Feed Pipe (1) » Reposition

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 15

26. Fuel Feed Pipe Bolt (1) » Remove
27. Fuel Feed Pipe (2) » Disconnect — Metal Collar Quick Connect Fitting Service
28. Fuel Feed Pipe (2) » Remove

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 16

Caution

Fuel feed intermediate pipes will be delivered with shipping caps that are meant to protect the mating joint threads. Do NOT remove shipping caps until the pipe is to be installed and joints are to be secured. Failure to do so could result in damage to the mating threads.

Note

Do NOT reuse the fuel feed intermediate pipe (2). If the 2 fuel feed intermediate pipe nuts (1) are loosened or the fuel feed intermediate pipes are removed, the fuel feed intermediate pipes MUST be replaced.

29. Fuel Feed Intermediate Pipe Nut (1) @ Fuel Feed Intermediate Pipe (2) » Loosen until disengaged [2x]
30. Fuel Feed Intermediate Pipe (2) » Remove and DISCARD

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 17

Note

Do NOT reuse the fuel feed intermediate pipe (3). If the 2 fuel feed intermediate pipe nuts (1) are loosened or the fuel feed intermediate pipes are removed, the fuel feed intermediate pipes MUST be replaced.

31. Fuel Feed Intermediate Pipe Nut (1) » Loosen until disengaged [2x]
32. Fuel Feed Pipe Bolt (2) » Remove
33. Fuel Feed Intermediate Pipe (3) » Remove and DISCARD
34. Disconnect and reposition the fuel pump and fuel injector wiring harness as necessary.

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 18

Caution

Alternately loosen the fuel pump bolts one turn at a time until the pump is fully disengaged from fuel pump lifter follower. Trying to remove the pump bolts without even side-to-side loosening may result in pump plunger damage

35. Fuel Pump Bolt (1) » Remove [2x]
36. Fuel Pump Cover (2) » Remove
37. Fuel Pump Bolt Retainer (3) » Remove [2x]
38. Fuel Pump (4) » Remove
39. Fuel Pump Bracket Gasket (5) » Remove and DISCARD
40. Clean the cylinder head around the fuel injectors on bank 1 of any dirt or buildup.

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 19

Note

The 4 bank 1 fuel injection fuel rail bolts (1) are retained in the bank 1 fuel injection fuel rail and may be difficult to remove.

41. Remove the 4 bank 1 fuel injection fuel rail bolts (1).

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 20

Note

In some cases, the fuel injectors may be difficult to remove because of heavy carbon build-up or other factors. If the fuel injectors are difficult to remove, apply solvent to the base of the fuel injector bores, and allow adequate soaking time, to loosen the fuel injectors. The bank 1 fuel injection fuel rail and fuel injectors are removed as an assembly. To prevent material from entering the combustions chambers make sure the area around each fuel injector is clean and free of debris before the fuel injectors are removed from the fuel injector bores.

42. Install 2 sets of EN-49248 Injector Rail Assembly Remover (1) on bank 1.
43. Install one EN-49248 Injector Rail Assembly Remover (1) in each of the bank 1 fuel injection fuel rail bolt bores.
44. Turn each EN-49248 Injector Rail Assembly Remover (1) an even amount to pull the fuel injection fuel rail bank 1 and fuel injectors out evenly.

Caution

Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components. Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages.

45. Simultaneously lift both ends of the bank 1 fuel injection fuel rail (2) and remove from the left side cylinder head.

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 21

46. Fuel Injector Nozzle Housing Seal (1) » Remove and DISCARD [8x]

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 22

47. Fuel Injector Seal (1) » Remove and DISCARD [4x]

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 23

48. Valve Rocker Arm Oil Control Valve Extension Harness (1) @ Valve Rocker Arm Oil Control Valve Harness » Disconnect

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 24

49. Engine Block Valley Cover Bolt (2) » Loosen until disengaged [9x]
50. Engine Block Valley Cover (1) » Remove

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 25

51. Engine Block Valley Cover Gasket (2) @ Engine Block Valley Cover (1) » Remove and DISCARD

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 26

52. Wiring Harness Connector Seal (1) @ Valve Rocker Arm Oil Control Valve Harness (2) » Remove and DISCARD

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 27

53. Positive Crankcase Ventilation Oil Separator Bolt (1) » Loosen until disengaged [4x]
54. Valve Rocker Arm Oil Control Valve Harness (2) @ Valve Lifter Oil Solenoid Valve » Disconnect [8x]
55. Valve Rocker Arm Oil Control Valve Harness (2) » 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.

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 28

1. Clean the engine block valley cover in solvent.
2. Dry with compressed air.
3. Inspect for damaged threads (1) and damaged sealing surfaces (2).

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 29

4. Clean all sealing surfaces.

5. Dry the intake manifold with compressed air.

6. Inspect the intake manifold cylinder head deck for warpage.

7. Place a straight edge (1) across the intake manifold cylinder head deck surface.

8. Inspect the intake manifold for the following conditions: 8.1. Inspect for loose threaded inserts or studs. 8.2. Inspect for damaged or broken vacuum fitting. 8.3. Inspect the intake manifold assembly for cracks or other damage. 8.4. Inspect for damaged intake manifold gasket sealing surfaces.

9. Position the straight edge (1) across a minimum of two runner port openings and check for warpage using a feeler gage. Engine Mechanical Specifications

10. Inspect the ventilation system passages for restrictions. Installation Procedure

11. Valve Rocker Arm Oil Control Valve Harness (2) @ Valve Lifter Oil Solenoid Valve » Connect [8x]

12. Positive Crankcase Ventilation Oil Separator Bolt (1) » Hand tighten [4x]

Caution

Refer to Fastener Caution.

3. Positive Crankcase Ventilation Oil Separator Bolt (1) » Tighten [4x] — Fastener Specifications

4. Wiring Harness Connector Seal (1) @ Valve Rocker Arm Oil Control Valve Harness (2) » Install NEW

Note

All gasket surfaces should be free of oil or other foreign material during assembly.

5. Engine Block Valley Cover Gasket (2) @ Engine Block Valley Cover (1) » Install NEW

6. Engine Block Valley Cover (1) » Install

7. Engine Block Valley Cover Bolt (2) » Hand tighten [9x]

8. Engine Block Valley Cover Bolt (2) » Tighten in sequence [9x] — Fastener Specifications

9. Valve Rocker Arm Oil Control Valve Extension Harness (1) @ Valve Rocker Arm Oil Control Valve Harness » Connect

Note

Do NOT use any type of lubricant when installing the NEW 4 bank 1 fuel injector seals (1) on the fuel injector.

10. Fuel Injector Seal (1) » Install NEW [4x]

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 30

Note

Do NOT use any type of lubricant when installing NEW seals (2) on the injector.

11. Install EN-51955-1 Long Protector (3) onto the fuel injector tip. Place a NEW seal (2) on EN- 51955-1 Long Protector. 11.1. Using EN-51955-4 Pusher (1), install the seal onto the first recessed area (4) of the fuel injector and remove EN-51955-4 Pusher.

Note

The EN-51955-5 Sizer is two sided, and either direction will size the seal correctly. 11.2. Compress the seal with your fingers, then resize the seal using the EN-51955-5 Sizer  (5).

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 31

Note

Do NOT use any type of lubricant when installing NEW seals (2) on the injector.

12. Install EN-51955-2 Short Protector (3) onto the fuel injector tip. Place a NEW seal (2) on EN- 51955-2 Short Protector. 12.1. Using EN-51955-4 Pusher (1), install the seal onto the second recessed area (4) of the fuel injector.

Note

The EN-51955-5 Sizer is two sided, and either direction will size the seal correctly. 12.2. Compress the seal with your fingers, then resize the seal using the EN-51955-5 Sizer  (5). 12.3.  Inspect the NEW fuel injector nozzle housing seals on ALL injectors, ensuring the seals are seated correctly. All seals must be fixed tight, and accurately to the fuel injector nozzle, with no overlap, buckling, or corrugation present. Replace any seal that is incorrectly seated on the fuel injector nozzle with a NEW seal.

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 32

Note

The fuel injection fuel rail bolts are retained into the rails using keepers. Care should be taken to ensure that the threadlock is installed after the fasteners are installed in their bore.

13. 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: 13.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 13.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 13.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 13.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

Note

Start the fuel injection fuel rail bolts by hand then draw the injector rail down evenly prior to tightening.

14. Fuel Injection Fuel Rail Bolt (1) @ Fuel Injection Fuel Rail (2) » Install [4x]
15. Install the fuel injection fuel rail assembly (2) to the cylinder head.
16. Fuel Injection Fuel Rail Bolt (1) » Tighten [4x] — Fastener Specifications
17. Connect the electrical wiring harness connectors to the fuel injection fuel rail.

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 33

Note

The camshaft must be in the base circle position before the fuel pump is installed.

18. Using EN-51092 Fuel Pump Installation Gauge (2) ensure that the camshaft lobe is in the base circle position. At base circle position, the EN-51092 Fuel Pump Installation Gauge (2) will be flush with the top surface of the lifter oil manifold assembly (1).

19. Ensure the 2 plastic fastener retainers (3) are installed in the fuel pump mounting holes before installing the fuel pump.

20. Fuel Pump Bracket Gasket (5) » Install NEW

21. Fuel Pump (4) » Install

22. Fuel Pump Cover (2) » Install

Caution

Alternately hand-tighten the fuel pump bolts one turn at a time until the pump is fully seated. Trying to draw down the pump without even side-to-side tightening may result in pump plunger damage.

23. Fuel Pump Bolt (1) » Install and hand tighten [2x]
24. Fuel Pump Bolt (1) » Tighten [2x] — Fastener Specifications
25. Reposition the fuel pump and fuel injector wiring harness and connect as necessary.

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 34

Note

Do NOT reuse the fuel feed intermediate pipe (1). If the 2 fuel feed intermediate pipe nuts (3) are loosened or the fuel feed intermediate pipes are removed, the fuel feed intermediate pipes MUST be replaced.

26. Fuel Feed Intermediate Pipe (1) » Install NEW 26.1. Slide the 2 fuel feed intermediate pipe nuts (3) back along fuel feed intermediate pipe  (1) to reveal the 2 formed ends (2) of the fuel feed intermediate pipe (1). 26.2. Carefully install the 2 formed ends (2) of the fuel feed intermediate pipe (1) into the sockets of the left and right fuel injection fuel rail. Take care not to hit the 2 formed ends  (2) of the fuel feed intermediate pipe (1) on the threaded sockets on the fuel injection fuel rails. 26.3. Hold the fuel feed intermediate pipe (1) firmly in place and hand tighten the 2 fuel feed intermediate pipe nuts (3).
27. Fuel Feed Pipe Bolt (4) » Tighten — Fastener Specifications
28. Fuel Feed Intermediate Pipe Nut (3) » Tighten [2x] — Fastener Specifications

Valve Rocker Arm Oil Control Valve Harness Replacement (L87) — figure 35

Note

Do NOT reuse the fuel feed intermediate pipe (1). If the 2 fuel feed intermediate pipe nuts (2) are loosened or the fuel feed intermediate pipes are removed, the fuel feed intermediate pipes MUST be replaced.

29. Fuel Feed Intermediate Pipe (1) » Install NEW 29.1. Slide the 2 fuel feed intermediate pipe nuts (2) back along fuel feed intermediate pipe  (1) to reveal the 2 formed ends (3) of the fuel feed intermediate pipe (1). 29.2. Carefully install the 2 formed ends (3) of the fuel feed intermediate pipe (1) into the sockets of the fuel pump (4) and the fuel feed intermediate pipe (5). Take care not to hit the 2 formed ends (3) of the fuel feed intermediate pipe (1) on the threaded sockets of the fuel pump (4) and fuel feed intermediate pipe (5). 29.3. Hold the fuel feed intermediate pipe (1) firmly in place and hand tighten the 2 fuel feed intermediate pipe nuts (2).

30. Fuel Feed Intermediate Pipe Nut (2) » Tighten [2x] — Fastener Specifications

31. Fuel Feed Pipe (2) » Install

32. Fuel Feed Pipe (2) » Connect — Metal Collar Quick Connect Fitting Service

33. Fuel Feed Pipe Bolt (1) » Install and tighten — Fastener Specifications

34. Fuel Feed Pipe (1) » Install

35. Fuel Feed Pipe (1) » Connect — Metal Collar Quick Connect Fitting Service

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. 36. Fuel Pump Insulator (1) » Install 37. Remove the covers from the cylinder head passages.

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

39. 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: 39.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 39.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 39.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 39.4. 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.

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

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

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

Note

Some components not shown for graphic clarity.

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

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

45. Positive Crankcase Ventilation Tube Connector (1) @ Intake Manifold » Install — Plastic Collar Quick Connect Fitting Service

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

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

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

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

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

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

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

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

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

55. Air Cleaner Outlet Duct (3) » Install

Caution

Refer to Component Fastener Tightening Caution.

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

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

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

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

60. Start the engine and check for fuel leaks.