Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87)

Engine Controls and Fuel - 5.3L L84 or 6.2L L87 | Repair Instructions | Document ID: 5906079 Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) Single Use Fasteners and Components Direct Fuel Injector Hold Down Clamp Fuel Feed Intermediate Pipe [2x] Fuel Injection Fuel Rail Seal [4x] Fuel Injector Nozzle Housing Seal Fuel Injector Seal [4x] Fuel Injector Seal Spacer [4x] Intake Manifold Gasket [8x] Special Tools EN-49248 Injector Rail Assembly Remover EN-51097 Injector Retaining Clip Installer EN-51955 Fuel Injector Seal Install/Sizer Equivalent regional tools: Special Tools

Warning

Refer to Safety Glasses Warning

Note

The quantity of fuel injector related single use components can vary depending on the number of fuel injectors to be replaced. Depending on available replacement kits, more components may be obtained than necessary for the current repair. Replace only the components necessary to complete the repair. Removal Procedure

1. Relieve the fuel pressure. Fuel Pressure Relief

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 1

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

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (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

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 3

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

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (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

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (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

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 6

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

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 7

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

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 8

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

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (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.

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 10

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

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (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 to prevent dirt or debris from entering the passages.

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 12

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

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (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. 23. Fuel Pump Insulator (1) » Remove

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 14

24. Fuel Feed Pipe Bolt (1) » Remove
25. Fuel Feed Pipe (2) » Disconnect — Metal Collar Quick Connect Fitting Service

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 15

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. If the fuel feed intermediate pipe fittings are loosened or the pipes are removed, the pipes MUST be replaced.

26. Fuel Feed Intermediate Pipe Nut (1) @ Fuel Feed Intermediate Pipe (2) » Loosen until disengaged [2x]
27. Fuel Feed Intermediate Pipe (2) » Remove and DISCARD
28. Disconnect the electrical wiring harness connectors as needed.

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 16

29. Fuel Feed Intermediate Pipe Nut (1) @ Fuel Feed Intermediate Pipe (3) » Loosen until disengaged
30. Fuel Feed Pipe Bolt (2) » Remove
31. Fuel Feed Intermediate Pipe (3) » Remove and DISCARD
32. Clean the cylinder head pocket around the injectors of any dirt or buildup.

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 17

Note

The fuel injection fuel rail bolts are retained in the fuel rail by keepers and may be difficult to remove.

33. Fuel Injection Fuel Rail Bolt (1) » Remove [4x]

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 18

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.

34. Install 2 sets of EN-49248 Injector Rail Assembly Remover (1) on bank 1.
35. Install one EN-49248 Injector Rail Assembly Remover (1) in each of the bank 1 fuel injection fuel rail bolt bores.
36. 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.

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 19

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.

37. Simultaneously lift both ends of the fuel rail (1) and remove the fuel rail assembly from the cylinder head.

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 20

38. Using the EN-51097 Injector Retaining Clip Installer (1), remove and DISCARD the direct fuel injector hold down clamps (2) from the fuel injector (3).
39. Remove the fuel injector (3) from the fuel rail.

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 21

40. Remove and DISCARD the 8 fuel injector nozzle housing seals (1) from the injectors.

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 22

41. Remove and DISCARD the 4 fuel injector seals (1) from the injectors.

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 23

42. Fuel Injection Fuel Rail Seal (1) » Remove and DISCARD [4x]
43. Fuel Injector Seal Spacer (2) » Remove and DISCARD [4x]

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 24

44. Fuel Rail Pressure Sensor (1) » Remove Cleaning and Inspection Procedure - Conditional

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 25

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

Refer to Component Fastener Tightening Caution.

1. Fuel Rail Pressure Sensor (1) » Install and tighten — Fastener Specifications

2. Fuel Injector Seal Spacer (2) » Install NEW [4x]

3. Fuel Injection Fuel Rail Seal (1) » Install NEW [4x]

4. Install the fuel injector (3) to the fuel rail.

5. Using the EN-51097 Injector Retaining Clip Installer (1), install NEW direct fuel injector hold down clamps (2) to the fuel injector (3).

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

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 26

Note

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

7. Install EN-51955-1 Long Protector (3) onto the fuel injector tip. Place a NEW seal (2) on EN- 51955-1 Long Protector. 7.1. 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. 7.2. Compress the seal with your fingers, then resize the seal using the EN-51955-5 Sizer (5).

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 27

Note

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

8. Install EN-51955-2 Short Protector (3) onto the fuel injector tip. Place a NEW seal (2) on EN- 51955-2 Short Protector. 8.1. 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. 8.2. Compress the seal with your fingers, then resize the seal using the EN-51955-5 Sizer (5). 8.3.  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.

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 28

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.

9. 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: 9.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 9.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 9.3. Remove loose debris from internal and external threads using compressed air. 9.4. Apply liquid thread locking adhesive in a strip along half of the length of the external threads, starting at the tip, just prior to installation. Adhesives, Fluids, Lubricants, and Sealers

Note

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

10. Fuel Injection Fuel Rail Bolt (1) @ Fuel Injection Fuel Rail (2) » Install [4x] — Fastener Specifications
11. Install the fuel injection fuel rail assembly (2) to the cylinder head.

Caution

Refer to Fastener Caution.

12. Fuel Injection Fuel Rail Bolt (1) @ Fuel Injection Fuel Rail (2) » Tighten [4x] — Fastener Specifications
13. Connect the electrical wiring harness connectors to the fuel rail as needed.

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 29

Note

Do NOT reuse the fuel feed intermediate pipe. If the fuel feed intermediate pipe fittings are loosened or the pipes are removed, the pipes MUST be replaced.

14. Fuel Feed Intermediate Pipe (1) » Install NEW 14.1. Slide fuel feed pipe fitting nuts (3) back along fuel feed intermediate pipe (1) to reveal the formed ends (2) of the fuel feed pipe. 14.2. Carefully install the formed ends (2) of the fuel feed pipe into the sockets of the left hand and right hand fuel rails, taking care not to hit the formed end of the pipes on the threaded sockets on the rails. 14.3. Hold the pipe firmly in place and hand tighten the fuel feed pipe fitting nuts (3) onto the threads on the fuel rails.
15. Fuel Feed Pipe Bolt (4) » Install and tighten — Fastener Specifications
16. Fuel Feed Intermediate Pipe Nut (3) @ Fuel Feed Intermediate Pipe (1) » Tighten [2x] — Fastener Specifications

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 30

Note

Do NOT reuse the fuel feed intermediate pipe. If the fuel feed intermediate pipe fittings are loosened or the pipes are removed, the pipes MUST be replaced.

17. Fuel Feed Intermediate Pipe (1) » Install NEW 17.1. Slide fuel feed pipe fitting nuts (2) back along fuel feed intermediate pipe (1) to reveal the formed ends (3) of the fuel feed pipe. 17.2. Carefully install the formed ends (3) of the fuel feed pipe into the sockets of the fuel pump (4) and fuel feed intermediate pipe (5), taking care not to hit the formed end of the pipes on the threaded sockets on the rails. 17.3. Hold the pipe firmly in place and hand tighten the fuel feed pipe fitting nuts (2) onto the threads on the fuel feed intermediate pipe (5) and the fuel pump (4).
18. Fuel Feed Intermediate Pipe Nut (2) @ Fuel Feed Intermediate Pipe (1) » Tighten [2x] — Fastener Specifications
19. Fuel Feed Intermediate Pipe Nut (2) @ Fuel Pump (4) » Tighten — Fastener Specifications

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (L87) — figure 31

20. Fuel Feed Pipe (2) » Install
21. Fuel Feed Pipe (2) » Connect — Metal Collar Quick Connect Fitting Service
22. Fuel Feed Pipe Bolt (1) » Install and tighten — Fastener Specifications

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) » Install

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

25. Remove the covers from the cylinder head passages.

26. Clean all sealing surfaces.

27. 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: 27.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 27.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 27.3. Remove loose debris from internal and external threads using compressed air. 27.4. Apply liquid thread locking adhesive in a strip along half of the length of the external threads, starting at the tip, just prior to installation. Adhesives, Fluids, Lubricants, and Sealers

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.

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

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

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

Note

Some components not shown for graphic clarity.

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

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

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

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

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

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

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

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

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

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

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

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

43. Air Cleaner Outlet Duct (3) » Install

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

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

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

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

48. Pressurize the fuel system and inspect for leaks.