Fuel Pump Replacement (L84)

Engine Controls and Fuel - 5.3L L84 or 6.2L L87 | Repair Instructions | Document ID: 5694421 Single Use Fasteners and Components Fuel Feed Intermediate Pipe Fuel Pump Bracket Gasket Intake Manifold Gasket [8x] Special Tools EN-51092 Fuel Pump Installation Gauge Equivalent regional tools: Special Tools Removal Procedure

Warning

Refer to Safety Glasses Warning.

1. Relieve the fuel system pressure. Fuel Pressure Relief

Fuel Pump 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 Pump 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 Pump Replacement (L84) — figure 3

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

Fuel Pump 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 Pump 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 Pump Replacement (L84) — figure 6

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

Fuel Pump Replacement (L84) — figure 7

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

Fuel Pump Replacement (L84) — figure 8

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

Fuel Pump 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 Pump Replacement (L84) — figure 10

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

Fuel Pump 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 Pump Replacement (L84) — figure 12

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

Fuel Pump 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 Pump Replacement (L84) — figure 14

24. Remove the fuel feed pipe bolt (1) and disconnect the fuel feed pipe (2) from the fuel pump. Metal Collar Quick Connect Fitting Service

Fuel Pump Replacement (L84) — 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.

25. Fuel Feed Intermediate Pipe Nut (1) @ Fuel Feed Intermediate Pipe (2) » Loosen until disengaged [2x]
26. Remove and DISCARD the fuel feed intermediate pipe (2).
27. Disconnect and reposition the fuel pump and fuel injector wiring harness as necessary.

Fuel Pump Replacement (L84) — figure 16

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

28. Fuel Pump Bolt (1) » Remove [2x]
29. Fuel Pump Cover (2) » Remove
30. Fuel Pump Bolt Retainer (3) » Remove [2x]
31. Remove the fuel pump (4) and fuel pump bracket gasket (5) from the engine.
32. DISCARD the fuel pump bracket gasket (5). 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 Replacement (L84) — figure 17

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

Fuel Pump Replacement (L84) — figure 18

Note

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

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

2. Install a NEW fuel pump bracket gasket (5).

3. Fuel Pump Bolt Retainer (3) » Install [2x]

Note

Ensure that the fuel pump roller lifter is oriented properly, the camshaft is at base circle and the number 1 piston is at top dead center (TDC) on the exhaust stroke.

4. Install the fuel pump (4) and fuel pump cover (2).

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.

Caution

Refer to Fastener Caution.

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

Fuel Pump Replacement (L84) — figure 19

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.

7. Fuel Feed Intermediate Pipe (1) » Install NEW 7.1. 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. 7.2. Carefully install the formed ends (3) of the fuel feed pipe into the sockets of the fuel pump (4) and the fuel feed intermediate pipe (5), taking care not to hit the formed end of the pipes on the threaded portion of the fuel pump and fuel feed intermediate pipe. 7.3. Hold the pipe firmly in place and hand tighten the fuel feed pipe fitting nuts (2) onto the threads on the fuel rails.

8. Fuel Feed Intermediate Pipe Nut (2) @ Fuel Feed Intermediate Pipe (1) » Tighten [2x] — Fastener Specifications

9. Connect the fuel feed pipe (2) to the fuel pump. Press the fuel feed pipe until an audible click is heard and then install the redundant clip. Metal Collar Quick Connect Fitting Service

10. 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. 11. Fuel Pump Insulator (1) » Install

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

13. Remove the covers from the cylinder head passages.

14. Clean all sealing surfaces.

15. 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: 15.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 15.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 15.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 15.4. 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.

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

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

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

Note

Some components not shown for graphic clarity.

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

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

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

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

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

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

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

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

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

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

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

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

31. Air Cleaner Outlet Duct (3) » Install

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

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

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

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

36. Pressurize the fuel system and inspect for leaks.