Engine Controls - 3.4l - Introduction - Service & Replacement

Temperature vs Resistance

°C	°F	OHMS
Temperature vs Resistance Values (Approximate)
150	302	47
140	284	60
130	266	77
120	248	100
110	230	132
100	212	177
90	194	241
80	176	332
70	158	467
60	140	667
50	122	973
45	113	1188
40	104	1459
35	95	1802
30	86	2238
25	77	2796
20	68	3520
15	59	4450
10	50	5670
5	41	7280
0	32	9420
5	23	12300
10	14	16180
15	5	21450
20	4	28680
30	22	52700
40	40	100700

Temperature vs Resistance

Altitude vs Barometric Pressure

Altitude Measured in Meters (m)	Altitude Measured in Feet (ft)	Barometric Pressure Measured in Kilopascals (kPa)
Determine your altitude by contacting a local weather station or by using another reference source.
4 267	14,000	56-64
3 962	13,000	58-66
3 658	12,000	61-69
3 353	11,000	64-72
3 048	10,000	66-74
2 743	9,000	69-77
2 438	8,000	71-79
2 134	7,000	74-82
1 829	6,000	77-85
1 524	5,000	80-88
1 219	4,000	83-91
914	3,000	87-95
610	2,000	90-98
305	1,000	94-102
0	0 Sea Level	96-104
305	1,000	101-105

Altitude vs Barometric Pressure

Ignition System Specifications

Application	Specification
Application	Metric	English
Firing Order	1-2-3-4-5-6
Spark Plug Wire Resistance	9868 ohms per meter (3000 ohms per ft)
Spark Plug Torque	15 N.m	11 lb ft
Spark Plug Gap	1.52 mm	0.060 in
Spark Plug Type	41-940

Ignition System Specifications

Fastener Tightening Specifications

Application	Specification
Application	Metric	English
Accelerator Cable Bracket Retaining Bolts	13 N.m	115 lb in
Accelerator Cable Bracket Retaining Nut	10 N.m	89 lb in
Accelerator Pedal Retaining Bolt	3 N.m	27 lb in
Air Cleaner Duct Clamp	2 N.m	18 lb in
Air Cleaner Housing Bolt	10 N.m	89 lb in
AIR Crossover Pipe Bolt	29 N.m	80 lb in
AIR Shut-off Valve	20 N.m	15 lb ft
AIR Shut-off Valve Nut	10 N.m	89 lb in
AIR Shut-off Valve Pipe Adapter Bolt	30 N.m	22 lb ft
Camshaft Position (CMP) Sensor Retaining Bolt	8 N.m	71 lb in
Crankshaft Position 7X (CKP) Sensor Bolts	11 N.m	97 lb in
Crankshaft Position 24X (CKP) Sensor Bolts	10 N.m	89 lb in
Engine Coolant Temperature (ECT) Sensor	20 N.m	15 lb ft
EVAP Canister Bracket Retaining Nut	10 N.m	89 lb in
EVAP Canister Purge Valve Bracket	10 N.m	89 lb in
EVAP Canister Retaining Nut	6 N.m	53 lb in
Exhaust Gas Recirculation Pipe Bolt	25 N.m	18 lb ft
Exhaust Gas Recirculation Pipe Nut	25 N.m	18 lb ft
Exhaust Gas Recirculation Valve Attaching Bolts	30 N.m	22 lb ft
Fuel Filler Pipe Attaching Nut	25 N.m	18 lb ft
Fuel Filler Pipe Attaching Screw	25 N.m	18 lb ft
Fuel Filler Pipe Clamp	2.5 N.m	22 lb in
Fuel Filter Mounting Bracket Nut	10 N.m	89 lb in
Fuel Pressure Regulator Attaching Bolt	8.5 N.m	76 lb in
Fuel Pressure and Return Pipes	17 N.m	13 lb ft
Fuel Rail Attaching Nuts or Bolts	10 N.m	89 lb in
Fuel Tank Filler Pipe Hose Clamp	2.5 N.m	22 lb in
Fuel Tank Retaining Strap Bolts	47 N.m	35 lb ft
Heated Oxygen Sensors	41 N.m	30 lb ft
Idle Air Control Valve Attaching Screws	3 N.m	27 lb in
Ignition Coil to Ignition Control Module Screws	4.5 N.m	40 lb in
Ignition Control Module Bracket to Engine Studs and Nuts	25 N.m	18 lb ft
Knock Sensor	19 N.m	14 lb ft
Manifold Absolute Pressure (MAP) Sensor Retaining Bolt	3 N.m	27 lb in
Powertrain Control Module (PCM) Electrical Connector Screws	8 N.m	71 lb in
Secondary AIR Injection Check Valve Bracket Nut	10 N.m	89 lb in
Secondary AIR Injection Check Valve Mounting Bolt	10 N.m	89 lb in
Secondary AIR Injection Pipe Nut	10 N.m	89 lb in
Secondary AIR Injection Pump Bracket Bolt	50 N.m	37 lb ft
Secondary AIR Injection Vacuum Bleed Valve Bracket Nut	10 N.m	89 lb in
Throttle Body Retaining Nuts or Bolts	28 N.m	21 lb ft
Throttle Position Sensor Screws	2 N.m	18 lb in

Fastener Tightening Specifications

Action Taken When the DTC Sets - Type A

The control module illuminates the malfunction indicator lamp (MIL) when the diagnostic runs and fails.

Action Taken When the DTC Sets - Type B

The control module illuminates the MIL on the second consecutive ignition cycle that the diagnostic runs and fails.

Conditions for Clearing the MIL/DTC - Type A or Type B

The control module turns OFF the MIL after 3 consecutive ignition cycles that the diagnostic runs and does not fail.
A current DTC Last Test Failed clears when the diagnostic runs and passes.
Use a scan tool in order to clear the MIL and the DTC.

Action Taken When the DTC Sets - Type C

The control module stores the DTC information into memory when the diagnostic runs and fails.
The MIL will not illuminate.
The driver information center, if equipped, may display a message.

Conditions for Clearing the DTC - Type C

A last test failed, or current DTC, clears when the diagnostic runs and passes.
Use a scan tool in order to clear the DTC.

Conditions for Clearing the DTC - Type X

This DTC is available in the PCM software, but has been disabled, or turned OFF. In this case, the diagnostic does not run, no DTCs are stored, and the MIL does not illuminate. Type X DTCs are used primarily for export vehicles that do not require MIL illumination or DTC storing.

Diagnostic Trouble Code (DTC) Type(s)

Diagnostic Trouble Code	Type
P0030	B
P0101	B
P0102	B
P0103	B
P0107	B
P0108	B
P0112	B
P0113	B
P0116	B
P0117	B
P0118	B
P0121	B
P0122	B
P0123	B
P0125	B
P0128	B
P0130	B
P0131	B
P0132	B
P0133	B
P0134	B
P0135	B
P0136	B
P0137	B
P0138	B
P0140	B
P0141	B
P0171	B
P0172	B
P0201	B
P0202	B
P0203	B
P0204	B
P0205	B
P0206	B
P0218	C
P0230	C
P0300	B
P0315	A
P0325	B
P0327	B
P0336	B
P0341	B
P0401	A
P0403	B
P0404	B
P0405	B
P0420	A
P0442	A
P0443	B
P0446	B
P0449	B
P0452	B
P0453	B
P0455	B
P0462	C
P0463	C
P0480	B
P0481	B
P0496	B
P0502	B
P0503	B
P0506	B
P0507	B
P0520	C
P0530	C
P0560	C
P0601	A
P0602	A
P0620	C
P0641	B
P0645	C
P0650	B
P0651	B
P0711	C
P0712	C
P0713	C
P0716	B
P0717	B
P0719	C
P0724	C
P0730	C
P0741	B
P0742	B
P0748	C
P0751	B
P0752	B
P0753	B
P0756	A
P0757	A
P0758	A
P0856	C (except M76)
P1106	C
P1107	C
P1111	C
P1112	C
P1114	C
P1115	C
P1121	C
P1122	C
P1133	B
P1134	B
P1351	B
P1352	B
P1361	B
P1362	B
P1374	B
P1380	C
P1381	C
P1404	B
P1554	C
P1585	C
P1626	C
P1630	C
P1631	C
P1640	C
P1650	C
P1660	C
P1670	C
P1689	C (except M76)
P1811	C
P1814	C
P1819	C
P1820	C
P1822	C
P1823	C
P1825	C
P1826	C
P1860	B
P1887	B
P2610	B
U1000	C
U1040	C
U1064	C
U1096	C
U1300	C
U1301	C

Diagnostic Trouble Code (DTC) Type(s)

Scheme 62

Scheme 62: Emission Hose Routing Diagram

Callout	Component Name
1	To Rocker Arm Cover
2	EVAP Service Port
3	To EVAP Canister (At Rear of Vehicle)
4	Air Intake Duct
5	Throttle Body
6	PCV Valve
7	Fuel Pressure Regulator
8	To Transaxle
9	Intake Manifold
10	To Accessory
11	To Vacuum Brake Booster
12	MAP Sensor
13	EVAP Canister Purge Valve

Scheme 63

Scheme 63: Evaporative Emissions (EVAP) Hose Routing Diagram

Callout	Component Name
1	EVAP Canister Purge Solenoid Valve
2	EVAP Canister
3	Fuel Fill Neck/Fill Cap
4	Rollover Valve/Fuel Tank Pressure (FTP) Sensor
5	Fuel Tank
6	EVAP Canister Vent Solenoid Valve
7	Vent Hose/Pipe
8	EVAP Vapor Pipe
9	EVAP Purge Pipe
10	EVAP Service Port

Scheme 64

Scheme 64: Fuel Hose/Pipes Routing Diagram

Callout	Component Name
1	Fuel Return Pipe Rear
2	Fuel Filter
3	Fuel Pump Module
4	Fuel Strainer
5	Fuel Feed Pipe Rear
6	Fuel Line Shut-off Adapters
7	Fuel Feed Pipe Front
8	Fuel Pressure Regulator
9	Fuel Rail
10	Fuel Injector
11	Fuel Pressure Gage
12	Bleed Hose
13	Fuel Return Pipe Front

Engine Controls Schematic Icons

Engine Controls Schematic Icons Icon Icon Definition NOTE: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit

Scheme 65

Scheme 65: Engine Controls Schematic Icons

Scheme 66

Scheme 66: Engine Controls Schematics

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

Scheme 75: Engine Controls Component Views

Callout	Component Name
1	Heat Shield
2	Catalytic Converter
3	Heated Oxygen Sensor (HO2S) 2

Scheme 76

Callout	Component Name
1	Crankshaft Position (CKP) Sensor A Connector and Bracket
2	Knock Sensor (KS) Connector
3	Engine Oil Pressure (EOP) Switch Connector
4	Starter Solenoid
5	Starter Motor
6	Fusible Links (Starter)
7	A/C Compressor Clutch Diode

Scheme 77

Callout	Component Name
1	Engine Oil Level Switch
2	Vehicle Speed Sensor (VSS)
3	Crankshaft Position (CKP) Sensor B
3	Heated Oxygen Sensor (HO2S) Sensor 1

Callout	Component Name
1	Crankshaft Position (CKP) Sensor A Connector and Bracket
2	Knock Sensor (KS) Connector
3	Engine Oil Pressure (EOP) Switch Connector
4	Starter Solenoid
5	Starter Motor
6	Fusible Links (Starter)
7	A/C Compressor Clutch Diode

Scheme 78

Callout	Component Name
1	Powertrain Control Module

Scheme 79

Callout	Component Name
1	Fuel Pump and Sender Assembly
2	Fuel Pump
3	Canister Vent Solenoid
4	EVAP Canister
5	Fuel Level Sender

Scheme 80

Callout	Component Name
1	Idle Air Control (IAC) Valve
2	Throttle Position (TP) Sensor

Scheme 81

Callout	Component Name
1	Fuel Injector 2
2	Fuel Injector 4
3	Fuel Injector 6
4	Fuel Rail
5	Fuel Injector 5
6	Fuel Injector 3
7	Fuel Injector 1

Scheme 82

Callout	Component Name
1	Upper Intake Manifold
2	Manifold Absolute Pressure (MAP) Sensor
3	Secondary Ignition (Spark Plug) Wires
4	Ignition Control Module (ICM) and Ignition Coils
5	Heated Oxygen Sensor (HO2S) Sensor 1
6	Crankshaft Position (CKP) Sensor B
7	Exhaust Gas Recirculation (EGR) Valve
8	Throttle Position (TP) Sensor
9	Fuel Feed and Return Pipes
10	Throttle Body
11	Idle Air Control (IAC) Valve
12	Positive Crankcase Ventilation (PCV) Valve
13	Evaporative Emission (EVAP) Canister Purge Solenoid
14	Camshaft Position (CMP) Sensor Harness Connector

Scheme 83

Callout	Component Name
1	Exhaust Gas Recirculation (EGR) Valve
2	Mass Air Flow (MAF) Sensor
3	Intake Air Temperature (IAT) Sensor

Scheme 84

Callout	Component Name
1	Camshaft Position (CMP) Sensor

Callout	Component Name
1	Heat Shield
2	Catalytic Converter
3	Heated Oxygen Sensor (HO2S) Sensor 2

Scheme 85

Callout	Component Name
1	Fuel Injection Wiring Harness
2	Engine Coolant Temperature (ECT) Sensor Connector
3	Engine Coolant Temperature (ECT) Sensor

Scheme 86

Callout	Component Name
1	Generator
2	Ignition Control Module (ICM)
3	Heated Oxygen Sensor (HO2S) 1
4	Ignition Coils

Powertrain Control Module (PCM) Connector End Views

Powertrain Control Module Connector End - C1 Connector Part Information 12191110 80-Way F Micro-Pack 100 Series Sealed (BLU) Pin Wire Color Circuit No. Function 1 BLK 2762 Low Reference 2-3 - - Not Used 4 LT GRN 1222 1-2 Shift Solenoid Valve Control 5 DK BLU 473 High Speed Cooling Fan Relay Control 6 DK GRN 335 Low Speed Cooling Fan Relay Control 7 BRN/WHT 633 CMP Sensor Signal 8 PPL/WHT 430 Low Resolution Engine Speed Signal 9 LT BLU/BLK 647 Medium Resolution Engine Speed Signal 10 GRY 2704 5-Volt Reference 11 - - Not Used 12 TAN 413 HO2S 1 Low Signal 13 ORN/BLK 469 Low Reference 14-15 - - Not Used 16 BLK/WHT 451 Ground 17 BLK 2760 Low Reference 18 - - Not Used 19 DK GRN 500 Ignition 0 Voltage 20 ORN 540 Battery Positive Voltage 21-27 - - Not Used 28 TAN/WHT 1669 HO2S 2 Low Signal 29 BLK 808 Low Reference 30 PPL 420 TCC Brake Switch/Cruise Control Release Signal 31 BLK 2753 Low Reference 32 GRY 435 EGR Solenoid Low Control 33 DK BLU 496 Knock Sensor Signal 34-37 - - Not Used 38 LT GRN/WHT 1749 IAC Coil B High Control 39-42 - - Not Used 43 BLK 1744 Fuel Injector 1 Control 44 YEL/BLK 1223 2-3 Shift Solenoid Valve Control 45 - - Not Used 46 PNK/BLK 1746 Fuel Injector 3 Control 47 LT GRN/BLK 1745 Fuel Injector 2 Control 48 RED/BLK 453 Low Reference 49-52 - - Not Used 53 TAN/BLK 424 IC Timing Signal 54 WHT 423 IC Timing Control 55 DK GRN 389 Vehicle Speed Signal 56 BLK/WHT 451 Ground 57 BLK/WHT 451 Ground 58 DK GRN 1049 PCM Class 2 Serial Data 59 - - Not Used 60 BLK/WHT 451 Ground 61 BLK 2752 Low Reference 62 DK BLU/WHT 1231 A/T ISS Low Signal 63 RED/BLK 1230 A/T ISS High Signal 64 YEL 400 VSS Signal High 65 PPL 401 VSS Signal Low 66-67 - - Not Used 68 YEL 772 Transmission Range Switch Signal B 69 YEL 492 MAF Sensor Signal 70-71 - - Not Used 72 DK GRN 83 Cruise Control Inhibit Signal 73 BLK/WHT 845 Fuel Injector 5 Control 74 LT BLU 1296 Axle Actuator Control (AWD) 75 - - Not Used 76 DK GRN/WHT 428 EVAP Canister Purge Solenoid Control 77-78 - - Not Used 79 YEL/BLK 846 Fuel Injector 6 Control 80 BLK 2751 Low Reference

Powertrain Control Module Connector End - C2 Connector Part Information 12191110 80-Way F Micro-Pack 100 Series Sealed (CLR) Pin Wire Color Circuit No. Function 1 - - Not Used 2 WHT 1310 EVAP Canister Vent Solenoid Control 3 DK GRN/WHT 465 Fuel Pump Relay Control 4 RED 1676 EGR Solenoid High Control 5 BRN/WHT 419 MIL Control 6 - - Not Used 7 LT BLU/WHT 1747 IAC Coil A High Control 8-9 - - Not Used 10 PPL 412 HO2S 1 High Signal 11 PPL/WHT 1668 HO2S 2 High Signal 12-15 - - Not Used 16 WHT 776 Transmission Range Switch Signal P 17 - - Not Used 18 BLK/WHT 771 Transmission Range Switch Signal A 19 TAN/BLK 231 Oil Pressure Switch Signal 20-22 - - Not Used 23 YEL 5 Crank Voltage 24 PNK 439 Ignition 1 Voltage 25 LT GRN 432 MAP Sensor Signal 26 YEL 410 ECT Sensor Signal 27 RED/BLK 380 A/C Refrigerant Pressure Sensor Signal 28 BRN 1456 EGR Valve Position Signal 29 - - Not Used 30 GRY 2702 5-Volt Reference 31 - - Not Used 32 GRY 2709 5-Volt Reference 33 GRY 2701 5-Volt Reference 34 GRY 2700 5-Volt Reference 35 BLK 2759 Low Reference 36 - - Not Used 37 BLK/WHT 3113 HO2S 1 Heater Low Control 38 - - Not Used 39 DK GRN/WHT 459 A/C Compressor Clutch Relay Control 40-41 - - Not Used 42 LT BLU/BLK 844 Fuel Injector 4 Control 43 - - Not Used 44 LT BLU/BLK 1748 IAC Coil A Low Control 45 RED/BLK 1228 PC Solenoid Valve High Control 46 LT BLU/WHT 1229 PC Solenoid Valve Low Control 47-48 - - Not Used 49 LT GRN/BLK 444 IAC Coil B Low Control 50 TAN 472 IAT Sensor Signal 51-54 - - Not Used 55 DK GRN 890 Fuel Tank Pressure Sensor Signal 56 GRY 773 Transmission Range Switch Signal C 57-58 - - Not Used 59 WHT 85 Cruise Control Engaged Signal 60 - - Not Used 61 RED 225 Generator Turn On Signal 62 - - Not Used 63 YEL 657 TCC Release Switch Signal 64-65 - - Not Used 66 DK BLU 417 TP Sensor Signal 67 - - Not Used 68 YEL/BLK 1227 TFT Sensor Signal 69 PPL 1589 Fuel Level Sensor Signal 70 LT GRN 1867 12-Volt Reference 71 - - Not Used 72 RED/WHT 812 12-Volt Reference 73 BLK 407 Low Reference 74 YEL/BLK 1868 Low Reference 75 BRN 436 AIR Pump Relay Control 76 YEL/BLK 625 Crank Relay Control 77 - - Not Used 78 BRN 418 TCC PWM Solenoid Valve Control 79 - - Not Used 80 BLK 808 Low Reference

Engine Controls Connector End Views

Camshaft Position (CMP) Sensor Connector End Connector Part Information 15336065 3-Way F Metri-Pack 150 Series Sealed (BLK) Pin Wire Color Circuit No. Function A RED/WHT 812 12-Volt Reference B BLK 407 Low Reference C BRN/WHT 633 CMP Sensor Signal

Crankshaft Position (CKP) Sensor A Connector End Connector Part Information 12110293 3-Way F Metri-Pack 150 Series Sealed (BLK) Pin Wire Color Circuit No. Function A LT GRN 1867 12-Volt Reference B LT BLU/BLK 647 Medium Resolution Engine Speed Signal C YEL/BLK 1868 Low Reference

Crankshaft Position (CKP) Sensor B Connector End Connector Part Information 12162194 2-Way F Metri-Pack 150.2 Series Sealed (BLK) Pin Wire Color Circuit No. Function A YEL 573 CKP Sensor 1 Signal B PPL 574 Low Reference

Engine Coolant Temperature (ECT) Sensor Connector End Connector Part Information 12162194 2-Way F Metri-Pack 150.2 Series Sealed (BLK) Pin Wire Color Circuit No. Function A ORN/BLK 469 Low Reference B YEL 410 ECT Sensor Signal

Evaporative Emission (EVAP) Canister Purge Solenoid Connector End Connector Part Information 12124037 2-Way F Metri-Pack 150 Series Sealed (BLK) Pin Wire Color Circuit No. Function A PNK 339 Ignition 1 Voltage B DK GRN/WHT 428 EVAP Canister Purge Solenoid Control

Evaporative Emission (EVAP) Canister Vent Solenoid Connector End Connector Part Information 12059863 2-Way F Metri-Pack 150 Series (BRN) Pin Wire Color Circuit No. Function A PNK 1239 Ignition 1 Voltage B WHT 1310 EVAP Canister Vent Solenoid Control

Scheme 87

Scheme 87: Engine Controls Connector End Views

Exhaust Gas Recirculation (EGR) Valve Connector End Connector Part Information 15326389 5-Way F Metri-Pack 150 (BLK) Pin Wire Color Circuit No. Function A GRY 435 EGR Solenoid Low Control B BLK 2753 Low Reference C BRN 1456 EGR Solenoid Position Signal D GRY 2702 5-Volt Reference E RED 1676 EGR Solenoid High Control

Fuel Injector 1 Connector End Connector Part Information 15326181 2-Way F (GRY) Pin Wire Color Circuit No. Function A PNK 639 Ignition 1 Voltage B BLK 1744 Fuel Injector 1 Control

Fuel Injector 2 Connector End Connector Part Information 15326181 2-Way F (GRY) Pin Wire Color Circuit No. Function A PNK 639 Ignition 1 Voltage B LT GRN/BLK 1745 Fuel Injector 2 Control

Fuel Injector 3 Connector End Connector Part Information 15326181 2-Way F (GRY) Pin Wire Color Circuit No. Function A PNK 639 Ignition 1 Voltage B PNK/BLK 1746 Fuel Injector 3 Control

Fuel Injector 4 Connector End Connector Part Information 15326181 2-Way F (GRY) Pin Wire Color Circuit No. Function A PNK 639 Ignition 1 Voltage B LT BLU/BLK 844 Fuel Injector 4 Control

Fuel Injector 5 Connector End Connector Part Information 15326181 2-Way F (GRY) Pin Wire Color Circuit No. Function A PNK 639 Ignition1 Voltage B BLK/WHT 845 Fuel Injector 5 Control

Fuel Injector 6 Connector End Connector Part Information 15326181 2-Way F (GRY) Pin Wire Color Circuit No. Function A PNK 639 Ignition 1 Voltage B YEL/BLK 846 Fuel Injector 6 Control

Fuel Pump and Sender Assembly Connector End Connector Part Information 12160482 4-Way F Metri-Pack 150 Series Sealed (BLK) Pin Wire Color Circuit No. Function A PPL 1589 Fuel Level Sensor Signal B GRY 120 Fuel Pump Supply Voltage C BLK 250 Ground D BLK 2759 Low Reference

Fuel Tank Pressure (FTP) Sensor Connector End Connector Part Information 12059595 3-Way F Metri-Pack 150 Series Sealed (BLK) Pin Wire Color Circuit No. Function A BLK/WHT 2759 Low Reference B DK GRN 890 Fuel Tank Pressure Sensor Signal C GRY/BLK 2709 5-Volt Reference

Heated Oxygen Sensor (HO2S) 1 Connector End Connector Part Information 12176897 4-Way F Metri-Pack 150 Sealed (GRY) Pin Wire Color Circuit No. Function A TAN 413 Low Reference B PPL 412 HO2S 1 High Signal C BLK/WHT 3113 HO2S 1 Heater Low Control D PNK 839 Ignition 1 Voltage

Heated Oxygen Sensor (H02S) 2 Connector End Connector Part Information 12160825 4-Way M Metri-Pack 150 Series (BLK) Pin Wire Color Circuit No. Function A TAN/WHT 1669 HO2S 2 Low Signal B PPL/WHT 1668 HO2S 2 High Signal C BLK 1050 Ground D PNK 839 Ignition 1 Voltage

Idle Air Control (IAC) Valve Connector End Connector Part Information 12162190 4-Way F Metri-Pack 150.2 Series Sealed P2S (BLK) Pin Wire Color Circuit No. Function A LT GRN/BLK 444 IAC Coil B Low Control B LT GRN/WHT 1749 IAC Coil B High Control C LT BLU/BLK 1748 IAC Coil A Low Control D LT BLU/WHT 1747 IAC Coil A High Control

Ignition Control Module (ICM) Connector End - C1 Connector Part Information 12162261 6-Way F Metri-Pack 150.2 Series (BLK) Pin Wire Color Circuit No. Function A TAN/BLK 424 IC Timing Signal B WHT 423 IC Timing Control C-D - - Not Used E PPL/WHT 430 Low Resolution Engine Speed Signal F RED/BLK 453 Low Reference

Scheme 88

Ignition Control Module (ICM Connector End - C2 Connector Part Information 12162184 2-Way F Metri-Pack 150.2 Series Sealed Pull To Seat (BLK) Pin Wire Color Circuit No. Function A YEL 573 CKP Sensor 1 Signal C PPL 574 Low Reference

Scheme 89

Ignition Control Module (ICM) Connector End - C3 Connector Part Information 12162194 2-Way F Metri-Pack 150.2 Series Sealed (BLK) Pin Wire Color Circuit No. Function A BLK/WHT 51 Ground B PNK/BLK 239 Ignition 1 Voltage

Intake Air Temperature (IAT) Sensor Connector End Connector Part Information 12162199 2-Way F 150.2 SER (MD GRY) Pin Wire Color Circuit No. Function A BLK 2760 Low Reference B TAN 472 IAT Sensor Signal

Knock Sensor (KS) Connector End Connector Part Information 12176800 1-Way F Metri-Pack 150 Series Sealed (GRY) Pin Wire Color Circuit No. Function 1 DK BLU 496 KS Signal

Manifold Absolute Pressure (MAP) Sensor Connector End Connector Part Information 12020403 3-Way M Weather Pack (GRN) Pin Wire Color Circuit No. Function A ORN/BLK 469 Low Reference B LT GRN 432 MAP Sensor Signal C GRY 2704 5-Volt Reference

Scheme 90

Mass Air Flow (MAF) Sensor Connector End Connector Part Information 12059595 3-Way F Metri-Pack 150 Series Sealed (BLK) Pin Wire Color Circuit No. Function A YEL 492 MAF Sensor Signal B BLK/WHT 451 Ground C PNK 339 Ignition 1 Voltage

Secondary Air Injection (AIR) Pump Connector End - NC8 Connector Part Information 12191968 2-Way F Metri-Pack 280 Series (GRY) Pin Wire Color Circuit No. Function A RED 78 AIR Pump Supply Voltage B BLK 1350 Ground

Scheme 91

Throttle Position (TP) Sensor Connector End Connector Part Information 12110192 3-Way F Metri-Pack 150 Series (BLK) Pin Wire Color Circuit No. Function A GRY 2701 5-Volt Reference B BLK 2752 Low Reference C DK BLU 417 TP Sensor Signal

Powertrain Control Module (PCM) Replacement

Service of the power control module (PCM) should normally consist of either replacement of the PCM or the electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for PCM replacement, inspect the PCM first to see if the PCM is the correct part. If the PCM is faulty, remove the PCM and install the new service PCM.

The new service PCM will not be programmed. You must program the new PCM. DTC P0602 indicates the EEPROM is not programmed or has malfunctioned.

There are no user serviceable parts in this PCM. The PCM should never be opened for any reason.

IMPORTANT

When replacing the production PCM with a service PCM (controller), it is important to transfer the broadcast code and production PCM number to the service PCM label. Do not record this information on the PCM cover. Transfer allows positive identification of PCM parts throughout the service life of the vehicle.

Removal Procedure

Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life.
Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (LA1)»(/buick/rendezvous/i-2001-2007/remont/charging-system/#battery-charging-system-and-starting-system) «Battery Negative Cable Disconnect/Connect Procedure (LY7)»(/buick/rendezvous/i-2001-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
Remove the left sheet metal diagonal brace. Refer to «Brace Replacement - Front Fender Upper Diagonal - Left»(/buick/rendezvous/i-2001-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
Remove the air cleaner assembly cover and lift the PCM from the assembly.
Disconnect the harness connectors from the PCM.
Remove the PCM from the engine compartment.

Installation Procedure

Install the PCM electrical connectors. Tighten: Tighten the PCM electrical connector screws to 8 N.m (71 lb in).
Install the PCM into the air cleaner assembly.
Install the air cleaner assembly cover.
Tighten the air cleaner assembly cover retainers.
Install the left sheet metal diagonal brace. Refer to «Brace Replacement - Front Fender Upper Diagonal - Left»(/buick/rendezvous/i-2001-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (LA1)»(/buick/rendezvous/i-2001-2007/remont/charging-system/#battery-charging-system-and-starting-system) «Battery Negative Cable Disconnect/Connect Procedure (LY7)»(/buick/rendezvous/i-2001-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
If a new PCM is being installed, program the EEPROM. Refer to «Service Programming System (SPS)»(/buick/rendezvous/i-2001-2007/remont/communication-devices/#service-programming-system) in Programming.

CKP System Variation Learn Procedure

Install a scan tool.
Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to «Diagnostic Trouble Code (DTC) List»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-diagnostic-information-and-procedures__diagnostic-trouble-code-dtc-list) for the applicable DTC.
Select the crankshaft position variation learn procedure with a scan tool.
The scan tool instructs you to perform the following: Accelerate to wide open throttle (WOT). Release throttle when fuel cut-off occurs. Observe fuel cut-off specification for applicable engine. Engine should not accelerate beyond calibrated RPM value. Release throttle immediately if value is exceeded. Block drive wheels. Set parking brake. DO NOT apply brake pedal. Cycle ignition from OFF to ON. Apply and hold brake pedal. Start and idle engine. Turn A/C OFF. Vehicle must remain in Park or Neutral. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC. Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC. Engine coolant temperature (ECT) - If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature.
Enable the crankshaft position system variation learn procedure with the scan tool and perform the following: IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. Accelerate to WOT. Release when fuel cut-off occurs. Test in progress.
The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to «DTC P0315»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-diagnosis-34l-dtc-p0140-dtc-p0496) . If any other DTCs set, refer to «Diagnostic Trouble Code (DTC) List»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-diagnostic-information-and-procedures__diagnostic-trouble-code-dtc-list) for the applicable DTC.
Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully.

The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set.

An engine replacement
A PCM replacement
A harmonic balancer replacement
A crankshaft replacement
A CKP sensor replacement
Any engine repairs which disturb the crankshaft to CKP sensor relationship

Turn OFF the ignition.
Drain the coolant below the level of the engine coolant temperature (ECT) sensor. Refer to «Draining and Filling Cooling System»(/buick/rendezvous/i-2001-2007/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
Disconnect the sensor electrical connector.
Carefully remove the ECT sensor.

Coat the threads with sealer P/N 9985253 or equivalent.
Install the ECT sensor. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
Connect the ECT sensor electrical connector.
Refill the cooling system. Refer to «Draining and Filling Cooling System»(/buick/rendezvous/i-2001-2007/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.

Disconnect the intake air temperature (IAT) sensor (1) electrical connector.
Carefully grasp the sensor and with a twisting and pulling motion, remove the IAT sensor from air intake duct.

Install the IAT sensor (1) by snapping into place.
Connect the IAT sensor electrical connector.

Turn OFF the ignition.
Disconnect the intake air temperature (IAT) sensor electrical connector.
Disconnect the mass air flow (MAF) sensor (1) electrical connector.
Remove the air inlet duct from the MAF sensor and the throttle body.
Remove the MAF sensor from the air filter housing.

Install the MAF sensor to the air filter housing.
Install the air inlet duct to the MAF sensor and the throttle body.
Connect the IAT sensor electrical connector.
Connect the MAF sensor (1) electrical connector.
Start and idle the engine.
Inspect the air intake duct for leaks.

Turn OFF the ignition.
Remove the screws that attach the manifold absolute pressure (MAP) sensor to the bracket.
Disconnect the MAP sensor electrical connector.
Disconnect the MAP inlet vacuum hose.
Remove the MAP sensor from the bracket.

Position the MAP sensor to the bracket.
Connect the MAP inlet vacuum hose.
Connect the MAP sensor electrical connector.
Install the screws. Tighten: Tighten the screws to 3 N.m (27 lb in).

Note. The Heated Oxygen Sensor (HO2S) and the Oxygen Sensor use a permanently attached pigtail and connector. Do not remove this pigtail from the Heated Oxygen Sensor. Damage or the removal of the pigtail or the connector could affect the proper operation of the sensor. Take care when handling the HO2S and the O2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Also avoid using cleaning solvents of any type. Do not drop the HO2S or the O2S. Do not roughly handle the HO2S or the O2S.

Disconnect the electrical connector.
Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/rendezvous/i-2001-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
Remove the heated oxygen sensor (HO2S).

Install the heated oxygen sensor (HO2S). Tighten: Tighten the HO2S 1 to 41 N.m (30 lb ft).
Lower the vehicle.
Connect the electrical connector.

Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/rendezvous/i-2001-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
Disconnect the electrical connector.
Remove the heated oxygen sensor (HO2S).

Install the heated oxygen sensor (HO2S). Tighten: Tighten the HO2S 2 to 41 N.m (30 lb ft).
Connect the electrical connector.
Lower the vehicle.

Turn OFF the ignition.
Remove the air intake duct. Refer to «Air Cleaner Intake Duct Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Disconnect the evaporative emission (EVAP) purge line.
Disconnect the fuel lines. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Disconnect the throttle position (TP) sensor electrical connector.
Remove the 2 TP sensor fasteners.
Remove the TP sensor and O-ring.

Install the TP sensor O-ring on the TP sensor.
Install the TP sensor on the throttle body assembly.
Install the 2 TP sensor fasteners, using a thread-locking compound on the screws. Loctite® 262, GM P/N #1052624, or equivalent should be used. Tighten: Tighten the TP sensor attaching screws to 2.0 N.m (18 lb in).
Connect the TP sensor electrical connector.
Connect the EVAP purge line.
Connect the fuel lines. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Install the air intake duct. Refer to «Air Cleaner Intake Duct Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .

Remove the throttle control cable bracket from the throttle body. Refer to «Accelerator Controls Cable Bracket Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Remove the canister purge solenoid valve. Refer to «Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Disconnect the idle air control (IAC) electrical connector.
Remove the idle air control valve attaching screws.
Remove the idle air control valve.
Remove the idle air control valve O-ring.

Install the new idle air control O-ring.
Install the idle air control valve into the throttle body.
Reinstall the idle air control valve attaching screws. Tighten: Tighten the screws to 3.0 N.m (27 lb in).
Connect the IAC electrical connector.
Install the canister purge solenoid valve. Refer to «Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Install the throttle control cable bracket. Refer to «Accelerator Controls Cable Bracket Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
The powertrain control module (PCM) will reset the idle air control valve whenever the ignition is turned ON, then OFF. Turn the ignition ON, then OFF.
Start the engine and allow the engine to reach operating temperature.

Remove the accelerator cable shield, if equipped.
Disconnect the accelerator cable from the throttle body lever.
Disconnect the accelerator cable from the accelerator cable bracket.
Remove the left instrument panel sound insulator. Refer to «Closeout/Insulator Panel Replacement - Left»(/buick/rendezvous/i-2001-2007/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gauges, and Console.
Disconnect the accelerator cable from the accelerator pedal.
Squeeze the accelerator cable cover tangs and push the accelerator cable through the bulkhead.
Remove the accelerator cable from the vehicle. Note the cable routing for aid in installation.

Install the accelerator cable into the vehicle using the routing noted during removal.
Install the snap retainer through the bulkhead.
Connect the accelerator cable through the slot in the accelerator pedal lever.
Seat the snap retainer in the accelerator pedal lever.
Connect the accelerator cable to the throttle body lever.
Connect the accelerator cable to the accelerator cable bracket.
Reinstall the accelerator cable shield, if equipped.
Inspect and check for complete throttle opening and closing positions by operating the accelerator pedal. Also check for poor carpet fit under the accelerator pedal.
Reinstall the left instrument panel sound insulator. Refer to «Closeout/Insulator Panel Replacement - Left»(/buick/rendezvous/i-2001-2007/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gauges, and Console.

Remove the left instrument panel sound insulator. Refer to «Closeout/Insulator Panel Replacement - Left»(/buick/rendezvous/i-2001-2007/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gauges, and Console.
Disconnect the accelerator cable from the accelerator pedal.
Remove the fasteners holding the accelerator pedal to the bulk head.
Remove the accelerator pedal.

Position the accelerator pedal to the bulkhead.
Reinstall the accelerator pedal bolt and stud. Tighten: Tighten the bolts and studs to 3.0 N.m (27 lb in).
Connect the accelerator cable to the accelerator pedal.
Check for complete throttle opening and closing positions by operating the accelerator pedal. Also inspect the carpet fit under the accelerator pedal.
Reinstall the left instrument panel sound insulator. Refer to «Closeout/Insulator Panel Replacement - Left»(/buick/rendezvous/i-2001-2007/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gauges, and Console.

Disconnect the accelerator cable cross slug from the throttle body lever.
Disconnect the accelerator cable from the accelerator cable bracket.
Disconnect the cruise control cable from the throttle lever and accelerator bracket, if applicable.
Remove the nut (3) and bolts (1, 2) holding the accelerator cable bracket to the throttle body.
Remove the accelerator cable bracket.

Position the accelerator cable bracket on the throttle body.
Install the nut (3) and bolts (1, 2). Tighten: Tighten the bolts in sequence (2, 1) to 13 N.m (115 lb in). Tighten the nut in sequence (3) to 10 N.m (89 lb in).
Connect the cruise control cable into accelerator cable bracket.
Connect the accelerator cable to the throttle body lever.
Connect the cruise control cable to the throttle lever and accelerator bracket, if applicable.

Drain coolant. Refer to «Draining and Filling Cooling System»(/buick/rendezvous/i-2001-2007/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
Disconnect the intake air temperature (IAT) sensor electrical connector.
Disconnect the breather tube from the air intake tube.
Remove the air intake tube.
Disconnect the idle air control (IAC) valve electrical connector.
Disconnect the throttle position (TP) sensor electrical connector.
Remove the accelerator control cable bracket. Refer to «Accelerator Controls Cable Bracket Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Disconnect the throttle body coolant bypass hoses.
Disconnect the heater pipe nut at the throttle body.
Remove the nuts and bolts holding the throttle body to the intake manifold.
Remove the throttle body assembly.

Clean the gasket surface on the intake manifold and the throttle body assembly.
Install a new gasket, if necessary.
Install the throttle body assembly.
Install the throttle body retaining nuts and bolts. Tighten: Tighten the throttle body retaining nuts and bolts to 28 N.m (21 lb ft).
Connect the throttle body coolant bypass hoses.
Connect the heater pipe nut at the throttle body.
Connect the idle air control (IAC) valve electrical connector.
Connect the throttle position (TP) sensor electrical connector.
Install the accelerator controls cable bracket. Refer to «Accelerator Controls Cable Bracket Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Install the air intake tube and tighten the clamps.
Connect the intake air temperature (IAT) sensor electrical connector.
Connect the breather tube to the air intake tube.
Refill the coolant. Refer to «Draining and Filling Cooling System»(/buick/rendezvous/i-2001-2007/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
Inspect for complete throttle opening and closing positions by operating the accelerator pedal. Also inspect for poor carpet fit under the accelerator pedal.

Throttle Body Cleaning Procedure

Remove the air cleaner outlet duct.
Remove the air inlet screen, if applicable.
Inspect the throttle body bore and the throttle valve plate for deposits. You must open the throttle valve in order to inspect all of the surfaces.
Clean the throttle body bore and the throttle valve plate using a clean shop towel with GM Top Engine Cleaner, P/N 1052626 or an equivalent product.
If the deposits are excessive, remove and disassemble the throttle body for cleaning. Refer to «Throttle Body Assembly Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) . After disassembly, clean the throttle body using a parts cleaning brush. DO NOT immerse the throttle body in any cleaning solvent.
If you removed and disassembled the throttle body for cleaning, assemble and install the throttle body. Refer to «Throttle Body Assembly Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Install the air inlet screen, if applicable.
Install the air cleaner outlet duct.

Fuel Pressure Relief Procedure

Tools Required

J 34730-1A Fuel Pressure Gage. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
J 34730-262 Fuel Pressure Gage Fitting. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .

Disconnect the negative battery terminal.
Install the J 34730-262 adaptor to the fuel pressure connection. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Connect the J 34730-1A to the fuel pressure connection. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) . Wrap a shop towel around the fuel pressure connection while connecting the fuel pressure gauge in order to avoid spillage.
Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing.
Drain any fuel remaining in the fuel pressure gauge into an approved container.
Remove the J 34730-1A and install the fuel pressure port cap. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .

Fuel Pressure Gage Installation and Removal

Tools Required

J 34730-1A Fuel Pressure Gage. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
J 34730-262 Fuel Pressure Gage Fitting. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .

Install the J 34730-1A with the. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) . J 34730-262 to the fuel pressure service connection, located on the fuel rail. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Turn ON the ignition.
Place the bleed hose of the fuel pressure gage into an approved gasoline container.
Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage.
Command the fuel pump ON with a scan tool until all of the air is bled out of the gage.
Close the bleed valve on the fuel pressure gage.
Command the fuel pump ON with a scan tool.
Inspect for fuel leaks with the following procedure: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.

Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure.
Place a shop towel under the fuel pressure gage adaptor fitting to catch any remaining fuel spillage.
Remove the J 34730-1A from the adaptor fitting. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Remove the J 34730-262 . See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Drain any fuel remaining in the fuel pressure gage into an approved container.
Install the cap on the fuel pressure connection.

Tools Required

J 37088-A Fuel Line Disconnect Tool Set. See Special Tools and Equipment .

Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement__fuel-pressure-relief-procedure) .
Remove the retainer from the quick-connect fitting.
Blow dirt out of the fitting using compressed air.
Choose the correct tool from the J 37088-A tool set for the size of the fitting. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) . Insert the tool into the female connector and push inward in order to release the locking tabs.
Pull the connection apart.
Using a clean shop towel, wipe off the male pipe end.
Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required.

Apply a few drops of clean engine oil to the male pipe end.
Push both sides of the fitting together in order to snap the retaining tabs into place.
Once installed, pull on both sides of the fitting in order to ensure the connection is secure.
Install the retainer to the quick-connect fitting.

Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement__fuel-pressure-relief-procedure) .
Blow dirt out of the fitting using compressed air.
Squeeze the plastic tabs on the male end connector.
Pull the connection apart.
Wipe off the male pipe end using a clean shop towel.
Inspect both ends of the fitting for dirt and burrs.
Clean or replace the components as required.

Apply a few drops of clean engine oil to the male pipe end.
Push both sides of the quick-connect fitting together in order to cause the retaining tabs to snap into place.
Pull on both sides of the quick connect fitting in order to make sure the connection is secure.

Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement__fuel-pressure-relief-procedure) .
Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/rendezvous/i-2001-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
Remove the quick-connect fitting (1) at the inlet of the in-pipe fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Drain any remaining fuel into an approved gasoline container.
Remove the in-pipe fuel filter mounting bracket nut (1) from stud.
Remove the quick-connect fitting (2) at the outlet of the in-pipe fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Remove the in-pipe fuel filter from the in-pipe fuel filter mounting bracket.

Remove the protective caps from the new in-pipe fuel filter.
Slide the in-pipe fuel filter into the in-pipe fuel filter mounting bracket.
Connect the quick-connect fitting at the outlet (2) of the in-pipe fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Install the in-pipe fuel filter and mounting bracket.
Install the in-pipe fuel filter mounting bracket retaining nut (1). Tighten: Tighten the in-pipe fuel filter mounting bracket nut (1) to 10 N.m (89 lb in).
Connect the quick-connect fitting at the inlet (1) of the in-pipe fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Lower the vehicle.
Reconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (LA1)»(/buick/rendezvous/i-2001-2007/remont/charging-system/#battery-charging-system-and-starting-system) «Battery Negative Cable Disconnect/Connect Procedure (LY7)»(/buick/rendezvous/i-2001-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
Inspect for fuel leaks. Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for leaks.

J 42960-2 Fuel Flapper Door Holder. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
J 45004 Fuel Tank Drain Hose. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .

CAUTION

Never drain or store fuel in an open container. Always use an approved fuel storage container in order to reduce the chance of fire or explosion.

CAUTION

Place a dry chemical (Class B) fire extinguisher nearby before performing any on-vehicle service procedures. Failure to follow these precautions may result in personal injury.

Remove the fuel filler cap.
Install the J 42960-2 into the fuel fill pipe in order to hold the door open. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Insert the J 45004 into the fuel tank until the hose reaches the bottom of the fuel tank. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Use an air operated pump device in order to drain as much fuel through the fuel fill pipe as possible.

Relieve the fuel system fuel pressure. Refer to «Fuel Pressure Relief Procedure»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement__fuel-pressure-relief-procedure) .
Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/rendezvous/i-2001-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
Disconnect the fuel tank wiring harness connector at the body pass through (1).
Disconnect the quick-connect fitting at the inlet side of the in-pipe fuel filter (1). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Disconnect the quick-connect fitting on the fuel return pipe, near the fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Disconnect the fuel tank evaporative emission (EVAP) pipe quick-connect fitting near the fuel filter.
Remove the fuel feed, the fuel return, and the EVAP lines from the fuel pipe retainer.
Remove the retaining nut for the EVAP canister bracket.
Loosen the fuel tank filler pipe hose clamp.
Disconnect the fuel tank filler pipe (2) from the fuel tank (1).
With the aid of an assistant, support the fuel tank and remove the fuel tank strap attaching bolts (2).
Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.
If the fuel tank is not being replaced, go to the Installation Procedure.
Disconnect the fuel tank wiring harness from the fuel sender assembly.
Remove the fuel sender shield from the fuel tank.
Disconnect the fuel feed and return pipe quick-connect fittings at the fuel sender (1). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Disconnect the EVAP vapor pipe assembly from the fuel sender.
Remove the fuel and/or EVAP pipe assembly from the fuel tank.
Remove the fuel sender assembly (1). Refer to «Fuel Sender Assembly Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Sender Assembly Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Remove the EVAP vent solenoid valve (2). Refer to «Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Remove the EVAP canister (3). Refer to «Evaporative Emission (EVAP) Canister Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .

Install the EVAP canister (3). Refer to «Evaporative Emission (EVAP) Canister Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Install the EVAP vent solenoid valve (2). Refer to «Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Install the fuel sender assembly (1). Refer to «Fuel Sender Assembly Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Sender Assembly Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Install the fuel and/or EVAP pipe assembly.
Connect the EVAP vapor pipe to the fuel sender assembly.
Connect the fuel feed and fuel return pipes at the fuel sender. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Install the fuel sender shield to the fuel tank. Tighten: Tighten the shield nuts to 6 N.m (53 lb in).
Connect the fuel tank wiring harness to the fuel sender assembly.
With the aid of an assistant, position and support the fuel tank.
Install the fuel tank retaining strap attaching bolts (2). Tighten: Tighten the fuel tank retaining strap bolts to 47 N.m (35 lb ft).
Install the EVAP canister retaining nut. Tighten: Tighten the EVAP canister retaining nut to 6 N.m (53 lb in).
Connect the fuel tank filler pipe (2) to the fuel tank (1). Tighten: Tighten the fuel tank filler pipe hose clamp to 2.5 N.m (22 lb in).
Connect the fuel feed pipe quick-connect fitting (1) at the inlet side of the fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Connect the fuel return pipe quick-connect fitting near the fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Connect the fuel tank EVAP pipe quick-connect fitting near the fuel filter.
Connect the fuel tank wiring harness connector (1) at the body pass-through.
Lower the vehicle.
Add fuel and reinstall the fuel tank filler pipe cap.
Connect the negative battery cable.
Inspect for fuel leaks with the following procedure: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.

Relieve the fuel system fuel pressure. Refer to «Fuel Pressure Relief Procedure»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-36l-ly7-introduction__fuel-pressure-relief-procedure) .
Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/rendezvous/i-2001-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
Disconnect the fuel tank wiring harness connector (1).
Disconnect the fuel pipes. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Remove the EVAP canister bracket nut.
Loosen the fuel tank fill pipe hose clamp.
Disconnect the fuel tank fill pipe (2) from the fuel tank (1).
Disconnect the EVAP vent pipe near the fill pipe hose. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
With the aid of an assistant or a transmission jack, support the fuel tank and remove the fuel tank strap attaching bolts (2).
Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.
If the fuel tank is being replaced, perform the following steps: Remove the fuel sender (1). Refer to «Fuel Sender Assembly Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Sender Assembly Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) . Remove the fuel tank wiring harness from the fuel tank. Remove the fuel pipes from the fuel tank. Remove the EVAP vent solenoid valve (2). Refer to «Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) . Remove the EVAP canister (3). Refer to «Evaporative Emission (EVAP) Canister Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .

Install the EVAP canister (3). Refer to «Evaporative Emission (EVAP) Canister Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Install the EVAP vent solenoid valve (2). Refer to «Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Install the fuel pipes to the fuel tank.
Install the fuel tank wiring harness to the fuel tank.
Install the fuel sender (1). Refer to «Fuel Sender Assembly Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Sender Assembly Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
With the aid of an assistant or a transmission jack, position and support the fuel tank.
Install the fuel tank strap bolts (2). Tighten: Tighten the fuel tank strap bolts to 47 N.m (35 lb ft).
Install the EVAP canister bracket nut. Tighten: Tighten the EVAP canister bracket nut to 6 N.m (53 lb in).
Install the EVAP vent pipe near the fill pipe hose. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Install the fuel tank filler pipe hose (2) to the fuel tank (1). Tighten: Tighten the fuel tank filler pipe hose clamp to 2.5 N.m (22 lb in).
Connect the fuel pipes. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Install the fuel tank wiring harness connector (1).
Lower the vehicle.
Add fuel as necessary and install the fuel tank filler pipe cap.
Inspect for fuel leaks. Perform the following steps: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.

Remove the fuel tank. Refer to «Fuel Tank Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Tank Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Disconnect the electrical connector from the fuel tank vapor pressure sensor.
Remove the fuel tank pressure sensor (1) from the modular fuel sender.

Install the new fuel tank pressure sensor (1) to the modular fuel sender.
Connect the electrical connector to fuel tank vapor pressure sensor.
Install the fuel tank. Refer to «Fuel Tank Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Tank Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .

Remove the fuel sender assembly. Refer to «Fuel Sender Assembly Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Sender Assembly Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Disconnect the fuel pump electrical connector (2).
Remove the fuel level sensor electrical connector retaining clip (4).
Disconnect the fuel level sensor electrical connector from under the fuel sender cover (5).
Remove the fuel level sensor retaining clip.
Squeeze the locking tangs and remove the fuel level sensor (3) from the modular fuel sender.

Install the fuel level sensor (3) to the modular fuel sender.
Install the fuel level sensor retaining clip.
Connect the fuel level sensor electrical connector.
Install the fuel level sensor electrical connector retaining clip (4).
Connect the fuel pump electrical connector (2).
Install the fuel sender assembly. Refer to «Fuel Sender Assembly Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Sender Assembly Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Inspect for fuel leaks with the following procedure: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.

Remove the fuel sender from the fuel tank. Refer to «Fuel Sender Assembly Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Sender Assembly Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) Engine Controls - 3.6L (LY7).
Disconnect the fuel level sensor electrical connector located in the module cover.
Use a small flat-bladed tool in order to disengage the fuel level sensor retainer.
Slide the fuel level sensor down in order to remove the fuel level sensor from the fuel sender module.

Slide the fuel level sensor up in order to install the fuel level sensor to the fuel sender module.
Ensure that the fuel level sensor retainer is properly engaged.
Connect the fuel level sensor electrical connector.
Install the fuel sender to the fuel tank. Refer to «Fuel Sender Assembly Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Sender Assembly Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) Engine Controls - 3.6L (LY7).

Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement__fuel-pressure-relief-procedure) .
Remove the fuel filler cap.
Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/rendezvous/i-2001-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
Remove the fuel filler pipe attaching nut to wheelhouse stud (1).
Remove the fuel filler pipe attaching screw (3) to the wheelhouse panel.
Loosen the fuel filler pipe clamp.
Remove the fuel filler pipe (2) from the fuel tank (1).
Remove the fuel filler pipe from the grommet on the fuel filler pocket (4).

Install the fuel filler pipe through grommet on the fuel fill pocket (4).
Install the fuel filler pipe (2) to the fuel tank (1). Fully seat the fill pipe to stop on the tank. Tighten: The fuel filler pipe clamp to 2.5 N.m (22 lb in).
Install the fuel filler pipe attaching screw (3) to the wheelhouse panel. Tighten: The fuel filler pipe attaching screw to 25 N.m (18 lb ft).
Install the fuel filler pipe attaching nut (1) to the wheelhouse panel. Tighten: Tighten the fuel filler pipe attaching nut to 25 N.m (18 lb ft).
Lower the vehicle.
Refill the fuel tank.
Tighten the fuel filler cap.
Reconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (LA1)»(/buick/rendezvous/i-2001-2007/remont/charging-system/#battery-charging-system-and-starting-system) «Battery Negative Cable Disconnect/Connect Procedure (LY7)»(/buick/rendezvous/i-2001-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
Inspect for fuel leaks with the following procedure: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.

J39765-A Fuel Sender Lock Ring Tool

Remove the fuel tank. Refer to «Fuel Tank Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Tank Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Remove the fuel sender shield fasteners.
Remove the fuel sender shield.
Disconnect the fuel sender electrical connectors.
Disconnect the fuel pipes from the fuel sender. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Use the J39765-A (1) in order to remove the fuel sender lock ring.
Remove the fuel sender from the fuel tank.
Remove and discard the fuel sender seal.

Clean the fuel sender sealing flange.
Install the NEW fuel sender seal to the fuel tank.
Install the fuel sender and the fuel sender lock ring.
Use the J39765-A (1) in order to install the fuel sender lock ring.
Install the fuel pipes to the fuel sender. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Install the fuel sender sensor electrical connectors.
Install the fuel sender shield.
Install the fuel sender shield nuts. Tighten: Tighten the nuts to 6 N.m (53 lb in).
Install the fuel tank. Refer to «Fuel Tank Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Tank Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .

J 45722 Fuel Sender Lock Ring Wrench

Remove the fuel tank. Refer to «Fuel Tank Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Tank Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Disconnect the fuel sender module electrical connectors.
Disconnect the fuel pipes from the fuel sender. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Use the J 45722 (1) and a long breaker-bar in order to unlock the fuel sender lock ring.
Remove the fuel sender lock ring (1) and the fuel sender (2) from the fuel tank.
Remove and discard the fuel sender seal (3).
Remove the fuel level sensor from the fuel sender module. Refer to «Fuel Level Sensor Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Level Sensor Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .

Install the fuel level sensor to the fuel sender module. Refer to «Fuel Level Sensor Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Level Sensor Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Clean the fuel sender sealing flange.
Install the NEW fuel sender seal (3) to the fuel tank seal groove.
Install the fuel sender (2) and the fuel sender lock ring (1).
Use the J 45722 (1) in order to install the fuel sender lock ring.
Install the fuel pipes to the fuel sender. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Install the fuel sender module electrical connectors.
Install the fuel tank. Refer to «Fuel Tank Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Tank Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .

Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement__fuel-pressure-relief-procedure) .
Clean all engine fuel pipe connections.
Clean areas surrounding the engine fuel pipe connections.
Disconnect the fuel feed and fuel return pipe quick-connect fitting in the engine compartment. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/rendezvous/i-2001-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
Disconnect the fuel return pipe quick-connect fitting near in-pipe fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Disconnect the fuel feed pipe quick-connect fitting on the engine-side of the in-pipe fuel filter (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Disconnect the evaporative emission (EVAP) pipe quick-connect fitting near in-pipe fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Cap the in-pipe fuel filter pipe, the fuel feed pipe, and the fuel return pipe as needed to stop any fuel leakage.
Remove the fuel feed, fuel return, and EVAP pipe attaching hardware, and the fuel feed, fuel return, and EVAP pipes.
Note the position of the fuel and EVAP pipes and the fuel and EVAP pipe attaching hardware for installation.
Inspect the pipes for bends, kinks, and cracks.
Replace the pipe or pipes as required.

Install the new fuel feed, fuel return, and EVAP pipes and attaching hardware as noted during removal.
Remove the caps from the in-pipe fuel filter pipe, the fuel feed pipe, and the fuel return pipe.
Connect the EVAP pipe quick-connect fitting near the in-pipe fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Connect the fuel return pipe quick-connect fitting near in-pipe fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Connect the fuel feed pipe quick-connect fitting at the outlet of the in-pipe fuel filter (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Lower the vehicle.
Connect the fuel feed and fuel return pipe quick-connect fittings in the engine compartment. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Inspect the fuel pipe clips and fasteners for proper installation.
Lower the vehicle.
Tighten the fuel fill cap.
Reconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (LA1)»(/buick/rendezvous/i-2001-2007/remont/charging-system/#battery-charging-system-and-starting-system) «Battery Negative Cable Disconnect/Connect Procedure (LY7)»(/buick/rendezvous/i-2001-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
Inspect for fuel leaks with the following procedure: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.

CAUTION

In order to Reduce the Risk of Fire and Personal Injury: If nylon fuel pipes are nicked, scratched or damaged during installation, Do Not attempt to repair the sections of the nylon fuel pipes. Replace them. When installing new fuel pipes, Do Not hammer directly on the fuel harness body clips as it may damage the nylon pipes resulting in a possible fuel leak. Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period. Before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.)

Note. Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

Remove the fuel tank. Refer to «Fuel Tank Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Tank Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Remove the fuel pipe attaching hardware.
Disconnect the fuel pipes from the fuel sender. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Remove the fuel feed and fuel return pipes from the fuel tank.

CAUTION

In order to Reduce the Risk of Fire and Personal Injury: If nylon fuel pipes are nicked, scratched or damaged during installation, they must be replaced.

Remove the shipping caps from the fuel pipes.
Install NEW quick-connect retainers to the fuel sender and pipes.
Install the fuel feed and fuel return pipes to the fuel tank.
Install the fuel pipes to the fuel sender. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Install the fuel pipe attaching hardware.
Install the fuel tank. Refer to «Fuel Tank Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Tank Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Inspect for fuel leaks with the following procedure: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.

Relieve the fuel system fuel pressure. Refer to «Fuel Pressure Relief Procedure»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement__fuel-pressure-relief-procedure) .
Clean all engine fuel pipe connections and areas surrounding the engine fuel pipe connections before disconnecting the engine fuel pipe connections to avoid possible contamination of the fuel system.
Disconnect the quick-connect fittings in the engine compartment. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Plug the chassis fuel feed pipe and the chassis fuel return pipe as required.
Remove the upper intake manifold assembly. Refer to «Intake Manifold Replacement - Upper»(/buick/rendezvous/i-2001-2007/remont/mechanical/#engine-mechanical-34l-la1) in Engine Mechanical.
Disconnect the engine fuel return pipe from the fuel pressure regulator. Discard the O-ring.
Disconnect the engine fuel feed pipe from the fuel rail. Discard the O-ring.

Lubricate the new O-ring with clean engine oil, then connect the O-ring and the engine fuel return pipe to the fuel pressure regulator.
Lubricate the new O-ring with clean engine oil, then connect the O-ring and the engine fuel feed pipe to the fuel rail. Tighten: Tighten the engine fuel pipe fittings to 17 N.m (13 lb ft).
Reinstall the upper intake manifold assembly. Refer to «Intake Manifold Replacement - Upper»(/buick/rendezvous/i-2001-2007/remont/mechanical/#engine-mechanical-34l-la1) in Engine Mechanical.
Connect the quick-connect fittings in the engine compartment. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Tighten the fuel fill cap.
Inspect for fuel leaks with the following procedure: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.

Fuel System Cleaning

Relieve the fuel system fuel pressure. Refer to «Fuel Pressure Relief Procedure»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement__fuel-pressure-relief-procedure) .
Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Remove the fuel tank. Refer to «Fuel Tank Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Tank Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Remove the fuel sender assembly. Refer to «Fuel Sender Assembly Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Sender Assembly Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Inspect the fuel pump inlet for dirt and debris. If dirt and debris are found, the fuel pump needs to be replaced.
Flush the fuel tank with hot water.
Pour the water out of the fuel sender assembly opening in the fuel tank. Rock the fuel tank in order to be sure that the removal of the water from the fuel tank is complete.
Allow the tank to dry completely before reassembly.
Install the fuel sender assembly. Refer to «Fuel Sender Assembly Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Sender Assembly Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Install the fuel tank. Refer to «Fuel Tank Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Tank Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Add fuel and install the fuel tank filler pipe cap.
Inspect for fuel leaks using the following procedure: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.

Note. Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination. Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail components. Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly.

An eight digit identification number is stamped on the left hand fuel rail (fueling even cylinders 2, 4, 6). Refer to this number if servicing or part replacement is required.

Relieve fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement__fuel-pressure-relief-procedure) .
Remove the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(/buick/rendezvous/i-2001-2007/remont/mechanical/#engine-mechanical-34l-la1) in Engine Mechanical.
Disconnect the engine fuel feed pipe at the fuel rail.
Disconnect the engine fuel return pipe from the fuel pressure regulator.
Remove and discard the fuel feed pipe and fuel return pipe O-rings.
Disconnect the fuel injector harness main electrical connector.
Pull up the lock release of the fuel injector connector (2).
Depress the lock tab (1) and lift the connector from the injector.
Repeat the previous two steps in order to disconnect all of the fuel injector electrical connectors.
Remove the fuel injector wiring harness.
Disconnect the coolant temperature sensor electrical connector.
Remove the fuel rail bolts.
Remove the fuel rail with the fuel injectors.
Remove the injector O-ring seal from the spray tip end of each injector.
If you are replacing the fuel rail, remove the fuel injectors from the fuel rail. Refer to «Fuel Injector Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) in Engine Controls.

CAUTION

In order to reduce the risk of fire and personal injury that may result from a fuel leak, always install the fuel injector O-rings in the proper position. If the upper and lower O-rings are different colors (black and brown), be sure to install the black O-ring in the upper position and the brown O-ring in the lower position on the fuel injector. The O-rings are the same size but are made of different materials.

If you are replacing the fuel rail, install the fuel injectors to the fuel rail. Refer to «Fuel Injector Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) in Engine Controls.
Install the fuel injector O-rings using GM P/N 12345616, (Canadian P/N 993182) or the equivalent.
Carefully install the fuel rail with the fuel injectors to the lower intake manifold.
Ensure that the nozzle ends of each fuel injector are located properly in the injector bores.
Press on the injector rail using the palms of both hands until the fuel injectors are fully seated.
Install the fuel rail bolts. Tighten: Tighten the fuel rail attaching bolt to 10 N.m (89 lb in).
Connect the coolant temperature sensor electrical connector.
Install the injector electrical harness to the fuel rail.
Apply grease GM P/N 12377900 (Canadian P/N 10953529) or equivalent to the fuel injector electrical connectors.
Install the fuel injector electrical connectors to the fuel injectors.
Push the slide locks (2) into position.
Connect the fuel injector harness main electrical connector.
Install new O-rings to the fuel feed pipe and fuel return pipe.
Connect the fuel feed pipe to the fuel rail. Tighten: Tighten the fuel feed pipe nut to 17 N.m (13 lb ft).
Connect the fuel return pipe to the fuel pressure regulator. Tighten: Tighten the fuel return pipe nut to 17 N.m (13 lb ft).
Install the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(/buick/rendezvous/i-2001-2007/remont/mechanical/#engine-mechanical-34l-la1) in Engine Mechanical.
Inspect for fuel leaks with the following procedure: Turn the ignition ON for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON. Inspect for fuel leaks.

Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement__fuel-pressure-relief-procedure) .
Disconnect the fuel pressure regulator vacuum line.
Remove the fuel pressure regulator retaining screw.
Using a shop towel to catch any spilled fuel, lift and twist the fuel pressure regulator in order to remove the fuel pressure regulator from the fuel rail.
Remove the retainer and spacer bracket from the rail and discard.
Remove the fuel pressure regulator from the engine fuel return pipe.
Remove the fuel pressure regulator inlet O-ring and discard.

Check the filter screen for contamination. If contaminated, replace the fuel pressure regulator.
Lubricate the new pressure regulator inlet O-ring with clean engine oil and install on the regulator inlet.
Install the fuel return pipe to the regulator.
Install the new retainer and spacer bracket into the slot on the fuel rail.
Install the pressure regulator to the fuel rail. Tighten: Tighten the engine fuel return pipe nut to 17 N.m (13 lb ft).
Connect the fuel pressure regulator vacuum line.
Install the pressure regulator attaching screw. Tighten: Tighten the pressure regulator attaching screw to 8.5 N.m (76 lb in).
Inspect and verify that the retainer and spacer bracket is engaged in the slots in the fuel rail. Grasp and pull on the regulator to ensure that the regulator is properly seated.
Inspect for fuel leaks with the following procedure: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.

Fuel Injector Cleaning Procedure

Tools Required

J 37287 Fuel Line Shut-Off Adapters. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
J 35800-A Fuel Injector Cleaner. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
J 42873-1 3/8 Fuel Line Shut-Off Valve. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
J 42873-2 5/16 Return Pipe Shut-Off Valve. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
J 42964-1 3/8 Fuel Pipe Shut-Off Valve. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
J 42964-2 5/16 Fuel Pipe Shut-Off Valve. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .

Note. GM Top-Engine Cleaner is the only injector cleaning agent recommended. Do not use other cleaning agents, as they may contain methanol which can damage fuel system components. Under NO circumstances should the top engine cleaner be added to the vehicles fuel tank, as it may damage the fuel pump and other system components. Do not exceed a 10 percent cleaning solution concentration. Higher concentrations may damage fuel system components. Testing has demonstrated that exceeding the 10 percent cleaning solution concentration does not improve the effectiveness of this procedure.

IMPORTANT

Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned. These vehicles should have the injectors replaced.

IMPORTANT

During this procedure you will need a total of 960 ml (32.4 oz) of cleaning solution. That is 2 tanks of solution for the J 35800-A . See Special Tools and Equipment . Other brands of tools may have a different capacity and would therefore require more or less tanks to complete the procedure. You must use all 960 ml (32.4 oz) of solution to ensure complete injector cleaning.

Obtain J 35800-A (2). See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
For US dealers, empty 2 pre-measured GM Top-Engine Cleaner containers, 24 ml (0.812 oz) each, GM P/N 12346535, into the J 35800-A . See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
For Canadian dealers, measure and dispense 48 ml (1.62 oz) of Top-Engine Cleaner, Canadian P/N 992872, into the J 35800-A . See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
If you are using any other brand of tank you will need a total of 96 ml (3.24 oz) of Top-Engine Cleaner mixed with 864 ml (29.16 oz) of regular unleaded gasoline.
Fill the injector cleaning tank with regular unleaded gasoline. Be sure to follow all additional instructions provided with the tool.
Electrically disable the vehicle fuel pump by removing the fuel pump relay and disconnecting the oil pressure switch connector, if equipped.
Disconnect the fuel feed and return line, if equipped, at the fuel rail. Plug the fuel feed and return line, if equipped, coming off the fuel rail with J 37287 , or J 42964-1 , and J 42964-2 or J 42873-1 , and J 42873-2 as appropriate for the fuel system. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Connect the J 35800-A to the vehicle fuel rail. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Pressurize the J 35800-A to 510 kPa (75 psi). See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Start and idle the engine until it stalls due to lack of fuel. This should take approximately 15-20 minutes.
Disconnect J 35800-A from the fuel rail. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped.
Remove J 37287 or J 42964-1 , and J 42964-2 or J 42873-1 , and J 42873-2 and reconnect the vehicle fuel feed and return lines. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Start and idle the vehicle for an additional 2 minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines.
Repeat steps 1-5 of the Injector Balance Test, and record the fuel pressure drop from each injector.
Subtract the lowest fuel pressure drop from the highest fuel pressure drop. If the value is 15 kPa (2 psi) or less, no additional action is required. If the value is greater than 15 kPa (2 psi), replace the injector with the lowest fuel pressure drop.
Add one ounce of Port Fuel Injector Cleaner, GM P/N 12345104 (Canadian P/N 10953467), to the vehicle fuel tank for each gallon of gasoline estimated to be in the fuel tank. Instruct the customer to add the reminder of the bottle of Port Fuel Injector Cleaner to the vehicle fuel tank at the next fill-up.
Advise the customer to change brands of fuel and to add GM Port Fuel Injector Cleaner every 5 000 km (3,000 mi). GM Port Fuel Injector Cleaner contains the same additives that the fuel companies are removing from the fuel to reduce costs. Regular use of GM Port Fuel Injector Cleaner should keep the customer from having to repeat the injector cleaning procedure.
Road test the vehicle to verify that the customer concern has been corrected.

Remove the fuel rail. Refer to «Fuel Rail Assembly Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Remove the fuel injector retaining clip (1).
Remove the fuel injector (3) from the fuel rail.
Remove the fuel injector upper O-ring (2).
Remove the fuel injector lower O-ring (4).

Install the fuel injector upper O-ring (2).
Install the fuel injector lower O-ring (4).
Install the fuel injector (3) to the fuel rail.
Install the fuel injector retaining clip (1).
Install the fuel rail. Refer to «Fuel Rail Assembly Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Inspect for fuel leaks with the following procedure: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.

Turn OFF the ignition.
Disconnect the evaporative emission (EVAP) canister purge valve electrical connector.
Disconnect the EVAP canister purge pipe from the EVAP canister purge valve.
Disconnect the vacuum supply hose from the EVAP canister purge valve.
Remove the EVAP canister purge valve retaining bolt.
Remove the EVAP canister purge valve from the intake manifold.

Position the EVAP canister purge valve on the intake manifold and install the retainer bolt. Tighten: Tighten the EVAP canister purge valve retaining bolt to 10 N.m (89 lb in).
Connect the EVAP canister purge pipe and the vacuum supply hose.
Connect the EVAP canister purge valve electrical connector.

Remove the fuel tank. Refer to «Fuel Tank Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Tank Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Disconnect the evaporative emission (EVAP) canister vent solenoid harness connector.
Remove the EVAP vent hose from EVAP canister solenoid.
Bend the EVAP canister vent bracket tab to release the EVAP canister vent solenoid.
Remove the EVAP canister solenoid (2) from the fuel tank.

Slide the EVAP canister vent solenoid (2) on the EVAP canister vent bracket until the solenoid snaps into place.
Connect the EVAP vent hose to the EVAP canister vent solenoid.
Connect the EVAP canister vent solenoid harness connector.
Install the fuel tank. Refer to «Fuel Tank Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Tank Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .

Remove the fuel tank. Refer to «Fuel Tank Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Tank Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Disconnect the evaporative emission (EVAP) purge pipe from the EVAP canister (3).
Remove the EVAP purge pipe from the vehicle.

Connect the EVAP purge pipe to the EVAP canister (3).
Install the fuel tank. Refer to «Fuel Tank Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Tank Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .

Disconnect the evaporative emission (EVAP) purge pipe from the EVAP canister purge valve.
Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/rendezvous/i-2001-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
Disconnect the EVAP purge pipe near the fuel filter.
Disconnect the EVAP purge pipe from the chassis attaching hardware.
Carefully remove the EVAP purge pipe from the chassis.

Position the EVAP purge pipe on the chassis
Snap the EVAP purge pipe into the chassis attaching hardware.
Connect the chassis EVAP purge pipe to the EVAP canister purge pipe located near the fuel filter.
Lower the vehicle.
Connect the EVAP purge pipe to the EVAP canister purge solenoid.

Remove the fuel tank. Refer to «Fuel Tank Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Tank Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Remove the 2 retaining nuts connecting the evaporative emission (EVAP) canister bracket to the fuel tank.
Reposition the EVAP canister (3) and disconnect the EVAP system hoses and/or pipes from the EVAP canister.
Remove the EVAP canister from the EVAP canister bracket.

Install the EVAP canister (3) on the EVAP canister bracket.
Connect the EVAP hoses/pipes to the EVAP canister.
Position the EVAP canister and bracket on the fuel tank and install the 2 retaining nuts. Tighten: Tighten the retaining nuts to 10 N.m (89 lb in).
Install the fuel tank. Refer to «Fuel Tank Replacement (Prior to VIN 4S558922 (100mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) «Fuel Tank Replacement (VIN 4S558922 and Later (130mm Sender))»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement)

Disconnect the spark plug wires. Note the position from which the wires are removed.
Remove the 2 screws that secure the ignition coil to the ignition control module.
Remove the ignition coil.

Install the ignition coil.
Install the 2 attaching screws. Tighten: Tighten the screws to 4.5 N.m (40 lb in).
Connect the spark plug wires.

Disconnect all the electrical connectors at the ignition control module (ICM).
Note the position of the spark plug wires for installation and disconnect the spark plug wires from the ignition coils.
Remove the screws securing the coil assemblies to the ignition control module.
Disconnect the coils from the ignition control module.
Remove the fasteners securing the ignition control module assembly to the engine.
Remove the ignition control module from the bracket.

Install the ignition control module on the bracket.
Install the coils to the ignition control module.
Reinstall the fasteners securing the ignition control module assembly to the engine.
Reinstall the screws. Tighten: Tighten the screws to 4.5 N.m (40 lb in).
Connect the spark plug wires as noted during removal.
Connect the electrical connectors to the ignition control module.

Spark Plug Wire Inspection

Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Refer to the list below for items to be inspected.

Inspect for correct routing of the spark plug wires. Improper routing may cause cross-firing.
Inspect each wire for any signs of cracks or splits in the wire.
Inspect each boot for the following conditions: Tearing Piercing Arcing Carbon tracking Corroded terminal

If corrosion, carbon tracking, or arcing are indicated on a spark plug wire boot or terminal, both the wire and the component connected to the wire should be replaced.

Turn the ignition OFF.
Remove the spark plug wires (2, 4, and 6) from the front bank spark plugs.
Remove the spark plug wires from the retaining clips.
Rotate the engine forward. Refer to «Rotating the Engine for Service Access»(/buick/rendezvous/i-2001-2007/remont/mechanical/#engine-mechanical-34l-la1) in Engine Mechanical.
Remove the spark plug wires (1, 3, and 5) from the rear bank spark plugs.
Remove the spark plug wires from the retaining clips.
Remove the spark plug wires from the ignition coils.
Remove the spark plug wires from the engine.
If you are replacing the spark plug wires, transfer any of the following components: Boot heat shields Spark plug wire conduit Spark plug wire retaining clips

Install the spark plug wires to the engine.
Install the spark plug wires to the ignition coils.
Install the spark plug wires (1, 3, and 5) to the rear bank spark plugs.
Install the spark plug wires to the retaining clips.
Return the engine to the proper position. Refer to «Rotating the Engine for Service Access»(/buick/rendezvous/i-2001-2007/remont/mechanical/#engine-mechanical-34l-la1) in Engine Mechanical.
Install the spark plug wires (2, 4, and 6) to the front bank spark plugs.
Install the spark plug wires to the retaining clips.

Spark Plug Inspection

Spark Plug Usage

Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to «Ignition System Specifications»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement__ignition-system-specifications) for the correct spark plug.
Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling-Colder plug Pre-ignition causing spark plug and/or engine damage-Hotter plug

Spark Plug Inspection

Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move.
Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground.
Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4).
Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to «Ignition System Specifications»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement__ignition-system-specifications) . An excessively wide electrode gap can prevent correct spark plug operation. Inspect for the correct spark plug torque. Refer to «Ignition System Specifications»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement__ignition-system-specifications) . Insufficient torque can prevent correct spark plug operation. An over-torqued spark plug causes the insulator (2) to crack. Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). Inspect for a broken or worn side electrode (3). Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. A loose center electrode (4) reduces the spark intensity. Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. Inspect for excess fouling.
Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation.

Spark Plug Visual Inspection

Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives.
Carbon fouled-Dry, fluffy, black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors Excessive fuel pressure Restricted air filter element Incorrect combustion Reduced ignition system voltage output Weak coils Worn ignition wires Incorrect spark plug gap Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off.
Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode.

Note. Observe the following service precautions: Allow the engine to cool before removing the spark plugs. Attempting to remove spark plugs from a hot engine can cause the spark plugs to seize. This can damage the cylinder head threads. Clean the spark plug recess area before removing the spark plug. Failure to do so can result in engine damage due to dirt or foreign material entering the cylinder head, or in contamination of the cylinder head threads. Contaminated threads may prevent proper seating of the new spark plug. Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either hotter or colder than those specified for the vehicle. Installing spark plugs of another type can severely damage the engine.

Turn the ignition OFF.
If you are replacing the engine right bank (rear) spark plugs, rotate the engine for service access. Refer to «Rotating the Engine for Service Access»(/buick/rendezvous/i-2001-2007/remont/mechanical/#engine-mechanical-34l-la1) in Engine Mechanical - 3.4L.
Remove the spark plug wires from the spark plugs. Refer to «Spark Plug Wire Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Remove the spark plugs from the engine.

Gap the spark plugs to the specifications. Refer to «Ignition System Specifications»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement__ignition-system-specifications) .
Install the spark plugs. Tighten: Tighten the spark plugs. If the spark plugs are installed into a NEW cylinder head, tighten the spark plugs to 20 N.m (15 lb ft). If the spark plugs are installed into an existing cylinder head, tighten the spark plugs to 15 N.m (11 lb ft).
Install the spark plug wires to the spark plugs. Refer to «Spark Plug Wire Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
If you are replacing the engine right bank (rear) spark plugs, return the engine to the proper position. Refer to «Rotating the Engine for Service Access»(/buick/rendezvous/i-2001-2007/remont/mechanical/#engine-mechanical-34l-la1) in Engine Mechanical - 3.4L.

Turn OFF the ignition.
Raise the vehicle on a hoist. Refer to «Lifting and Jacking the Vehicle»(/buick/rendezvous/i-2001-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information
Remove the crankshaft harmonic balancer. Refer to «Crankshaft Balancer Replacement»(/buick/rendezvous/i-2001-2007/remont/mechanical/#engine-mechanical-34l-la1__crankshaft-balancer-replacement) in Engine Mechanical.
Note the routing of the sensor harness before removal.
Remove the harness retaining clip (3) with the bolt (4).
Disconnect the sensor electrical connector.
Remove the sensor bolts (4).
Remove the sensor (1).

Install the 24X crankshaft position sensor (1) with bolts (4) and the route harness as noted during removal.
Install the harness retaining clip (3) with the bolt (4). Tighten: Tighten the bolts to 10 N.m (89 lb in).
Connect the sensor electrical connector.
Install the balancer on the crankshaft. Refer to «Crankshaft Balancer Replacement»(/buick/rendezvous/i-2001-2007/remont/mechanical/#engine-mechanical-34l-la1__crankshaft-balancer-replacement) in Engine Mechanical.
Lower vehicle.
Perform the CKP System Variation Learn Procedure. Refer to «CKP System Variation Learn Procedure»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement__ckp-system-variation-learn-procedure) .

Turn OFF the ignition.
Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/rendezvous/i-2001-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
Access the crankshaft position sensor. For front-wheel drive vehicles, remove the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/buick/rendezvous/i-2001-2007/remont/wheel-tire-system/#tires-and-wheels) in Tire and Wheel. For all-wheel-drive vehicles, disconnect the catalytic converter from the exhaust manifold and reposition.
Disconnect the sensor electrical connector.
Remove the attaching bolt and/or screw.
Remove the sensor from the engine.
Inspect for wear, cracks, or leakage if the sensor is not being replaced.

Replace the O-ring, if it is damaged. Lubricate the O-ring with clean engine.
Install the sensor to the block.
Install the sensor attaching bolt. Tighten: Tighten the bolt to 11 N.m (97 lb in).
Install the sensor electrical connector.
Install components that were removed. For front-wheel-drive vehicles, install the right tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/buick/rendezvous/i-2001-2007/remont/wheel-tire-system/#tires-and-wheels) in Tire and Wheel. For all-wheel-drive vehicles, install the catalytic converter to the exhaust manifold. Refer to «Catalytic Converter Replacement»(/buick/rendezvous/i-2001-2007/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
Lower the vehicle.
Perform the CKP System Variation Learn Procedure. Refer to «CKP System Variation Learn Procedure»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement__ckp-system-variation-learn-procedure) .

Turn OFF the ignition.
Remove the power steering pump. Refer to «Power Steering Pump Replacement (LA1 )»(/buick/rendezvous/i-2001-2007/remont/manual-power-steering/#power-steering-system) «Power Steering Pump Replacement (LY7)»(/buick/rendezvous/i-2001-2007/remont/manual-power-steering/#power-steering-system) in Power Steering System.
Disconnect the sensor electrical connector.
Remove the attaching bolt.
Remove the sensor.
Inspect the sensor O-ring for wear, cracks, or leakage if the sensor is not being replaced.

Lubricate the O-ring with clean engine oil. Replace the O-ring if the O-ring is damaged.
Install the camshaft position sensor. Tighten: Tighten the retaining bolt to 8 N.m (71 lb in).
Connect the sensor electrical connector.
Install the power steering pump. Refer to «Power Steering Pump Replacement (LA1 )»(/buick/rendezvous/i-2001-2007/remont/manual-power-steering/#power-steering-system) «Power Steering Pump Replacement (LY7)»(/buick/rendezvous/i-2001-2007/remont/manual-power-steering/#power-steering-system) in Power Steering System.

Turn OFF the ignition.
Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/rendezvous/i-2001-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
Disconnect the wiring harness connector from the knock sensor.
Remove the knock sensor from the engine block.

Install the knock sensor into the engine block. Tighten: Tighten the knock sensor to 19 N.m (14 lb ft).
Connect the knock sensor wiring harness connector to the knock sensor.
Lower the vehicle.

Turn OFF the ignition.
Disconnect the EGR valve electrical connector.
Remove the transaxle fluid filler tube. Refer to «Fluid Filler Tube Replacement (LA1)»(/buick/rendezvous/i-2001-2007/remont/automatic-trans/#automatic-transaxle-4t65-e-introduction-service-replacement) «Fluid Filler Tube Replacement (LY7)»(/buick/rendezvous/i-2001-2007/remont/automatic-trans/#automatic-transaxle-4t65-e-introduction-service-replacement) in Automatic Transaxle - 4T65-E.
Remove the bolt retaining the pipe assembly from the EGR valve and carefully pull the pipe assembly back.
Remove the EGR valve retaining bolts.
Remove the EGR valve assembly.
Remove the gasket.
Clean the EGR valve mating surface.

Install the EGR valve with a new gasket to the intake manifold.
Install the bolts through the EGR valve. Tighten: Tighten the bolts to 30 N.m (22 lb ft).
Connect the pipe assembly to the EGR valve.
Install the bolt. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
Install the transaxle fluid filler tube. Refer to «Fluid Filler Tube Replacement (LA1)»(/buick/rendezvous/i-2001-2007/remont/automatic-trans/#automatic-transaxle-4t65-e-introduction-service-replacement) «Fluid Filler Tube Replacement (LY7)»(/buick/rendezvous/i-2001-2007/remont/automatic-trans/#automatic-transaxle-4t65-e-introduction-service-replacement) in Automatic Transaxle - 4T65-E
Connect the EGR valve electrical connector.

Turn the ignition OFF.
Apply the parking brake.
Raise the front of the vehicle approximately 100mm (4 in.) with a floor jack. Refer to «Lifting and Jacking the Vehicle»(/buick/rendezvous/i-2001-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
Remove the two front frame bolts.
Slowly lower the frame and powertrain approximately 100mm (4 in.) from the underbody rails in order to gain access to the EGR pipe.
Place two jack stands beneath the frame to prevent any movement of the frame and powertrain assembly.
Remove the EGR pipe bolt and the EGR pipe from the EGR valve.
Loosen the EGR pipe nut in order to remove the EGR pipe from the exhaust manifold.
Remove the EGR pipe.

Install the EGR pipe to the exhaust manifold. Tighten: Tighten the EGR pipe nut to 25 N.m (18 lb ft).
Install the EGR pipe and the EGR pipe bolt to the EGR valve. Tighten: Tighten the EGR pipe bolt to 25 N.m (18 lb ft).
Use the floor jack in order to raise the frame and powertrain until the frame contacts the underbody rails.
Install the frame bolts. Refer to «Frame Replacement - Front (W/AWD)»(/buick/rendezvous/i-2001-2007/remont/frames-subframes-crossmembers/#frame-and-underbody) «Frame Replacement - Front (W/FWD)»(/buick/rendezvous/i-2001-2007/remont/frames-subframes-crossmembers/#frame-and-underbody) in Frame and Underbody.
Remove the jack stands.
Lower and remove the floor jack.
Release the parking brake.

Exhaust Gas Recirculation (EGR) System Cleaning

CAUTION

Avoid breathing fumes and swallowing EGR exhaust deposits when removing components for cleaning as bodily injury may result.

IMPORTANT

Whenever the exhaust gas recirculation (EGR) valve is removed, the EGR system should be inspected and cleaned if needed. This will ensure that the EGR system will function properly under all operating conditions.

Proper EGR system service consists of the following steps

Turn OFF the ignition.
Clean and inspect the EGR pipe from the exhaust manifold to the EGR valve. Refer to «Exhaust Gas Recirculation (EGR) Pipe Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Clean the EGR valve. The EGR valve can be removed, inspected for deposits, cleaned, and reinstalled. Use the following procedure for this operation: Remove the EGR valve from the engine. Refer to «Exhaust Gas Recirculation (EGR) Valve Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) . While holding the EGR valve base in your hand, try to rotate the connector housing. Replace the valve that exhibits looseness. Inspect the EGR valve pintle and seat for deposits. Use a cloth or other suitable soft device to remove deposits. Remove all loose particles. If deposits are such that pintle and/or base interface cannot be cleaned adequately to allow the pintle to seal against the seat, replace the valve. Damage to the EGR valve base will occur if cleaned with solvents, sharp tools, wire brush, wheel or sand blasting. Cleaning by these methods is not recommended. Install the EGR valve on the engine using a new gasket. Refer to «Exhaust Gas Recirculation (EGR) Valve Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .

Loosen the 2 intake air duct clamps (1) from the mass airflow (MAF) sensor (2) and the throttle body.
Remove the intake air temperature (IAT) sensor from the duct. Refer to «Intake Air Temperature (IAT) Sensor Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Disconnect the vent tube from the air intake duct.
Disconnect the MAF sensor electrical connector.
Unlatch the air cleaner cover clips (1) and remove the air intake duct and air cleaner cover.
Separate the air intake duct from the MAF sensor.

Install the air intake duct to the MAF sensor.
Install the air intake duct to the throttle body and the air cleaner cover to the air cleaner assembly.
Latch the air cleaner cover clips (1).
Reconnect the MAF sensor electrical connector (2).
Reconnect the vent tube to the air intake duct.
Install the IAT sensor.
Tighten the 2 intake air duct clamps (1). Tighten: Tighten the intake air duct clamps to 2 N.m (18 lb in).

Remove the air cleaner intake duct. Refer to «Air Cleaner Intake Duct Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement)
Remove the filter element (1) from the air cleaner housing (2).

Install the filter element (1) into the air cleaner housing.
Install the air cleaner intake duct.

Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (LA1)»(/buick/rendezvous/i-2001-2007/remont/charging-system/#battery-charging-system-and-starting-system) «Battery Negative Cable Disconnect/Connect Procedure (LY7)»(/buick/rendezvous/i-2001-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
Remove the coolant reservoir. Refer to «Coolant Recovery Reservoir Replacement»(/buick/rendezvous/i-2001-2007/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
Remove the cruise control module. Refer to «Cruise Control Module Replacement»(/buick/rendezvous/i-2001-2007/remont/cruise-control-systems/#cruise-control-system) in Cruise Control.
Remove the left front sheet metal diagonal brace. Refer to «Brace Replacement - Front Fender Upper Diagonal - Left»(/buick/rendezvous/i-2001-2007/remont/exterior-body-panels/#body-front-end) or «Brace Replacement - Front Fender Upper Diagonal - Right»(/buick/rendezvous/i-2001-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
Remove the air cleaner side cover and the air cleaner element. Refer to «Air Cleaner Element Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Remove the air cleaner upper cover bolts and the air cleaner upper cover.
Remove and reposition the powertrain control module (PCM) with the wiring harness.
Remove the air cleaner bolts and the air cleaner.

Install the air cleaner.
Install the air cleaner bolts. Tighten: Tighten the air cleaner bolts to 10 N.m (89 lb in).
Install the PCM and the wiring harness to the air cleaner.
Install the air cleaner side cover and element. Refer to «Air Cleaner Element Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-34l-introduction-service-replacement) .
Install the air cleaner upper cover and the upper cover bolts. Tighten: Tighten the air cleaner upper cover bolts to 4 N.m (35 lb in).
Install the left front sheet metal diagonal brace. Refer to «Brace Replacement - Front Fender Upper Diagonal - Left»(/buick/rendezvous/i-2001-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
Install the coolant reservoir. Refer to «Coolant Recovery Reservoir Replacement»(/buick/rendezvous/i-2001-2007/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
Install the cruise control module. Refer to «Cruise Control Module Replacement»(/buick/rendezvous/i-2001-2007/remont/cruise-control-systems/#cruise-control-system) in Cruise Control.
Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (LA1)»(/buick/rendezvous/i-2001-2007/remont/charging-system/#battery-charging-system-and-starting-system) «Battery Negative Cable Disconnect/Connect Procedure (LY7)»(/buick/rendezvous/i-2001-2007/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.

Powertrain

The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM.

The following are some of the functions that the PCM controls

The engine fueling
The ignition control (IC)
The knock sensor (KS) system
The evaporative emissions (EVAP) system
The secondary air injection (AIR) system (if equipped)
The exhaust gas recirculation (EGR) system
The automatic transmission functions
The generator
The A/C clutch control
The cooling fan control

Powertrain Control Module Function

The powertrain control module (PCM) constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected.

Malfunction Indicator Lamp (MIL) Operation

The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON

Scheme 92

Scheme 92: Malfunction Indicator Lamp (MIL) Operation

Scheme 93

The MIL indicates that an emissions related fault has occurred and vehicle service is required.

The following is a list of the modes of operation for the MIL

The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate.
The MIL turns OFF after the engine is started if a diagnostic fault is not present.
The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate.
The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter.
When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON.
When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON.

Trip

A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the powertrain control module (PCM), allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e., misfire).

Warm-Up Cycle

The powertrain control module (PCM) uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160°F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction.

Diagnostic Trouble Codes (DTCs)

The powertrain control module (PCM) is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the malfunction indicator lamp (MIL) or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records.

The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text.

There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type.

DTC Status

When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set.

System Overview

The fuel tank stores the fuel supply. An electric fuel pump, located in the fuel tank within the modular fuel sender assembly, pumps fuel through an in-line fuel filter to the fuel rail assembly. The pump provides fuel pressure greater than is needed by the injectors. The fuel pressure regulator keeps fuel available to the injectors at a regulated pressure. A separate fuel pipe is used to return fuel to the fuel tank.

Scheme 94

Scheme 94: Fuel Tank

The fuel tank stores the fuel supply. The fuel tank is located in the rear of the vehicle. The fuel tank is held in place by two metal straps that secure it to the vehicle. The fuel tank is molded from high density polyethylene.

Scheme 95

Scheme 95: Fuel Fill Pipe

The fuel fill pipe has a built-in restrictor and deflector In order to prevent refueling with leaded fuel.

Fuel Filler Cap

Note. If a fuel tank filler cap requires replacement, use only a fuel tank filler cap with the same features. Failure to use the correct fuel tank filler cap can result in a serious malfunction of the fuel and EVAP system.

The fuel fill pipe has a tethered fuel fill cap. A torque-limiting device prevents the cap from being over tightened. To install the cap, turn the cap clockwise until you hear audible clicks. This indicates that the cap is correctly torqued and fully seated. A fuel fill cap that is not fully seated may cause a malfunction in the emission system.

Scheme 96

Scheme 96: Fuel Sender Assembly

The fuel sender assembly consists of the following major components

The fuel level sensor
The fuel tank pressure (FTP) sensor (1)
The fuel tank pump module
The fuel strainer

Scheme 97

Scheme 97: Fuel Level Sensor

The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the Class 2 circuit to the instrument panel (IP) cluster. This information is used for the IP fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics.

Scheme 98

Scheme 98: Fuel Pump

The fuel pump is mounted in the fuel sender assembly reservoir. The fuel pump is an electric high pressure pump. Fuel is pumped to the fuel rail at a specified flow and pressure. Excess fuel from the fuel rail assembly returns to the fuel tank through the fuel return pipe. The fuel pump delivers a constant flow of fuel to the engine even during low fuel conditions and aggressive vehicle maneuvers. The powertrain control module (PCM) controls the electric fuel pump operation through a fuel pump relay. The fuel pump flex pipe acts to dampen the fuel pulses and noise generated by the fuel pump.

Fuel Pump Strainer

The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. The fuel strainer is self-cleaning and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or water. The fuel pump strainer is a part of the fuel sender assembly and is not serviceable.

Scheme 99

Scheme 99: Fuel Filter

The fuel filter is located on the fuel feed pipe, between the fuel pump and the fuel injectors. The paper filter element (2) traps particles in the fuel that may damage the fuel injection system. The filter housing (1) is made to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. There is no service interval for fuel filter replacement. Replace a restricted fuel filter.

Fuel Feed and Fuel Return Pipes

The fuel feed pipe carries fuel from the fuel tank to the fuel rail assembly. The fuel return pipe carries fuel from the fuel rail assembly back to the fuel tank. The fuel pipes consist of 2 sections

The rear fuel pipe assemblies are located from the top of the fuel tank to the chassis fuel pipes. The rear fuel pipes are constructed of nylon.
The chassis fuel pipes are located under the vehicle and connect the rear fuel pipes to the fuel rail pipes. These pipes are constructed of steel.

Nylon Fuel Pipes

CAUTION

Refer to Fuel and EVAP Pipe Caution in Cautions and Notices.

Nylon pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. There are 3 sizes of nylon pipes used

3/8 in. ID for the fuel feed
5/16 in. ID for the fuel return
1/2 in. ID for the vent

Heat resistant rubber hose or corrugated plastic conduit protect the sections of the pipes that are exposed to chafing, high temperature, or vibration.

Nylon fuel pipes are somewhat flexible and can be formed around gradual turns under the vehicle. However, if nylon fuel pipes are forced into sharp bends, the pipes kink and restrict the fuel flow. Also, once exposed to fuel, nylon pipes may become stiffer and are more likely to kink if bent too far. Take special care when working on a vehicle with nylon fuel pipes.

Quick-Connect Fittings

Quick-connect fittings provide a simplified means of installing and connecting fuel system components. The fittings consist of a unique female connector and a compatible male pipe end. O-rings, located inside the female connector, provide the fuel seal. Integral locking tabs inside the female connector hold the fittings together.

Fuel Pipe O-Rings

O-rings seal the threaded connections in the fuel system. Fuel system O-ring seals are made of special material. Service the O-ring seals with the correct service part.

Scheme 100

Scheme 100: Fuel Rail Assembly

The fuel rail assembly attaches to the engine intake manifold. The fuel rail assembly performs the following functions

Positions the injectors in the intake manifold
Distributes fuel evenly to the injectors
Integrates the fuel pressure regulator with the fuel metering system

Scheme 101

Scheme 101: Fuel Injectors

The Multec 2 fuel injector assembly is a solenoid operated device, controlled by the PCM, that meters pressurized fuel to a single engine cylinder. The PCM energizes the high-impedance (12.0 ohms) injector solenoid (2) to open a normally closed ball valve (3). This allows fuel to flow into the top of the injector, past the ball valve, and through a director plate at the injector outlet. The director plate has four machined holes that control the fuel flow, generating a spray of finely atomized fuel at the injector tip. Fuel from the injector tip is directed at the intake valve, causing it to become further atomized and vaporized before entering the combustion chamber. An injector stuck partly open can cause a loss of pressure after engine shutdown. Consequently, long cranking times would be noticed on some engines.

Scheme 102

Scheme 102: Fuel Pressure Regulator Assembly

The fuel pressure regulator is a vacuum operated diaphragm relief valve with fuel pump pressure on one side and regulator spring pressure and intake manifold vacuum on the other side. The fuel pressure regulator maintains a constant pressure differential across the injectors at all times. The pressure regulator compensates for engine load by increasing fuel pressure as the engine vacuum drops.

Fuel Metering Modes of Operation

The powertrain control module (PCM) monitors voltages from several sensors in order to determine how much fuel to give the engine. The fuel is delivered under one of several conditions called modes. The PCM controls all modes.

Starting Mode

With the ignition switch in the ON position, before engaging the starter, the PCM energizes the fuel pump relay for 2 seconds allowing the fuel pump to build up pressure. The PCM first tests speed density, then switches to the mass air flow (MAF) sensor. The PCM also uses the engine coolant temperature (ECT), the throttle position (TP), and the manifold absolute pressure (MAP) sensors to determine the proper air/fuel ratio for starting. The PCM controls the amount of fuel delivered in the starting mode by changing the pulse width of the injectors. This is done by pulsing the injectors for very short times.

Clear Flood Mode

If the engine floods, clear the engine by pressing the accelerator pedal down to the floor and then crank the engine. When the throttle position (TP) sensor is at wide open throttle (WOT), the PCM reduces the injector pulse width in order to increase the air to fuel ratio. The PCM holds this injector rate as long as the throttle stays wide open and the engine speed is below a predetermined RPM. If the throttle is not held wide open, the PCM returns to the starting mode.

Run Mode

The run mode has 2 conditions called Open Loop and Closed Loop. When the engine is first started and the engine speed is above a predetermined RPM, the system begins Open Loop operation. The PCM ignores the signal from the heated oxygen sensor (HO2S) and calculates the air/fuel ratio based on inputs from the engine coolant temperature (ECT), mass air flow (MAF), manifold absolute pressure (MAP), and throttle position (TP) sensors. The system stays in Open Loop until meeting the following conditions

Both heated oxygen sensors (HO2S) have varying voltage output, showing that they are hot enough to operate properly. This depends upon the engine temperature.
The ECT sensor is above a specified temperature.
A specific amount of time has elapsed after starting the engine.

Specific values for the above conditions exist for each different engine, and are stored in the electrically erasable programmable read-only memory (EEPROM). The system begins Closed Loop operation after reaching these values. In Closed Loop, the PCM calculates the air/fuel ratio (injector on-time) based upon the signal from various sensors, but mainly from the HO2S. This allows the air/fuel ratio to stay very close to 14.7:1.

Acceleration Mode

When the driver pushes on the accelerator pedal, air flow into the cylinders increases rapidly, while fuel flow tends to lag behind. To prevent possible hesitation, the PCM increases the pulse width to the injectors to provide extra fuel during acceleration. The PCM determines the amount of fuel required based upon the throttle position, the coolant temperature, the manifold air pressure, the mass air flow, and the engine speed.

Deceleration Mode

When the driver releases the accelerator pedal, air flow into the engine is reduced. The PCM reads the corresponding changes in throttle position, manifold air pressure, and mass air flow. The PCM shuts OFF fuel completely if the deceleration is very rapid, or for long periods, such as long, closed-throttle coast-down. The fuel shuts OFF in order to protect the catalytic converters.

Battery Voltage Correction Mode

When the battery voltage is low, the PCM compensates for the weak spark delivered by the ignition system in the following ways

Increasing the amount of fuel delivered
Increasing the idle RPM
Increasing the ignition dwell time

Fuel Cutoff Mode

The PCM cuts off fuel from the fuel injectors when the following conditions are met in order to protect the powertrain from damage and improve driveability

The ignition is OFF. This prevents engine run-on.
The ignition is ON but there is no ignition reference signal. This prevents flooding or backfiring.
The engine speed is too high, above red line.
The vehicle speed is too high, above rated tire speed.
During an extended, high speed, closed throttle coast down-This reduces emissions and increases engine braking.
During extended deceleration, in order to protect the catalytic converters

Short Term Fuel Trim

The short term fuel trim values change rapidly in response to the HO2S signal voltages. These changes "fine tune" the engine fueling. The ideal fuel trim values are around 0 percent. A positive fuel trim value indicates that the PCM is adding fuel in order to compensate for a lean condition. A negative fuel trim value indicates that the PCM is reducing the amount of fuel in order to compensate for a rich condition.

When the PCM determines that the short term fuel trim is out of the operating range, the following diagnostic trouble codes (DTCs) will set

DTC P0171 Bank 1 Too Lean
DTC P0172 Bank 1 Too Rich

Long Term Fuel Trim

The long term fuel trim is a matrix of cells arranged by RPM and manifold absolute pressure (MAP). Each cell of the long term fuel trim is a register like the short term fuel trim. As the engine operating conditions change, the PCM will switch from cell to cell to determine what long term fuel trim factor to use in the base pulse width equation.

While in any given cell, the PCM also monitors the short term fuel trim. If the short term fuel trim is far enough from 0 percent, the PCM will change the long term fuel trim value. Once the long term fuel trim value is changed, the change should force the short term fuel trim back toward 0 percent. If the mixture is still not correct, the short term fuel trim will continue to have a large deviation from the ideal 0 percent. In this case, the long term fuel trim value will continue to change until the short term fuel trim becomes balanced. Both the short term fuel trim and long term fuel trim have limits which vary by calibration. If the mixture is off enough so that long term fuel trim reaches the limit of control and still cannot correct the condition, the short term fuel trim would also go to the limit of control in the same direction. If the mixture is still not corrected by both short term fuel trim and long term fuel trim at these extreme values, a fuel trim diagnostic trouble code (DTC) will likely result. When the PCM determines that the long term fuel trim is out of the operating range, the following DTCs will set

DTC P0171 Bank 1 Too Lean
DTC P0172 Bank 1 Too Rich

Under the conditions of power enrichment, the PCM sets the short term fuel trim to 0 percent until power enrichment is no longer in effect. This is done so the Closed Loop factor and the long term fuel trim will not try to correct for the power enrichment condition.

EVAP System Operation

The evaporative emission (EVAP) control system limits fuel vapors from escaping into the atmosphere. Fuel tank vapors are allowed to move from the fuel tank, due to pressure in the tank, through the vapor pipe, into the EVAP canister. Carbon in the canister absorbs and stores the fuel vapors. Excess pressure is vented through the vent line and EVAP vent solenoid to atmosphere. The EVAP canister stores the fuel vapors until the engine is able to use them. At an appropriate time, the control module will command the EVAP purge solenoid ON, open, allowing engine vacuum to be applied to the EVAP canister. With the EVAP vent solenoid OFF, open, fresh air will be drawn through the solenoid and vent line to the EVAP canister. Fresh air is drawn through the canister, pulling fuel vapors from the carbon. The air/fuel vapor mixture continues through the EVAP purge pipe and EVAP purge solenoid into the intake manifold to be consumed during normal combustion. The control module uses several tests to determine if the EVAP system is leaking.

Large Leak Test

This tests for large leaks and blockages in the EVAP system. The control module will command the EVAP vent solenoid ON, closed, and command the EVAP purge solenoid ON, open, with the engine running, allowing engine vacuum into the EVAP system. The control module monitors the fuel tank pressure (FTP) sensor voltage to verify that the system is able to reach a predetermined level of vacuum within a set amount of time. The control module then commands the EVAP purge solenoid OFF, closed, sealing the system and monitors the vacuum level for decay. If the control module does not detect that the predetermined vacuum level was achieved, or the vacuum decay rate is more than a calibrated level on 2 consecutive tests, a DTC P0455 will set.

Small Leak Test

If the large leak test passes, the control module will test for small leaks by continuing to monitor the FTP sensor for a change in voltage over a period of time. If the decay rate is more than a calibrated value, the control module will rerun the test. If the test fails again, a DTC P0442 will set.

Canister Vent Restriction Test

If the EVAP vent system is restricted, fuel vapors will not be properly purged from the EVAP canister. The control module tests this by commanding the EVAP purge solenoid ON, open; and commanding the EVAP vent solenoid OFF, open; and monitoring the FTP sensor for an increase in vacuum. If vacuum increases more than a calibrated value, DTC P0446 will set.

Purge Solenoid Leak Test

If the EVAP purge solenoid does not seal properly, fuel vapors could enter the engine at an undesired time, causing driveability concerns. The control module tests for this by commanding the EVAP purge solenoid OFF, closed; and vent solenoid ON, closed; sealing the system, and monitoring the FTP for an increase in vacuum. If the control module detects that EVAP system vacuum increases above a calibrated value, DTC P0496 will set.

Check Gas Cap Message

The PCM sends a class 2 message to the Driver Information Center (DIC) illuminating the Check Gas Cap message when any of the following occur

A malfunction in the EVAP system and a large leak test fails
A malfunction in the EVAP system and a small leak test fails

EVAP System Components

The EVAP system consists of the following components

EVAP Canister

The canister is filled with carbon pellets used to absorb and store fuel vapors. Fuel vapor is stored in the canister until the control module determines that the vapor can be consumed in the normal combustion process.

EVAP Purge Solenoid

The EVAP purge solenoid controls the flow of vapors from the EVAP system to the intake manifold. This normally closed solenoid is pulse width modulated (PWM) by the control module to precisely control the flow of fuel vapor to the engine. The solenoid will also be opened during some portions of the EVAP testing, allowing engine vacuum to enter the EVAP system.

EVAP Vent Solenoid

The EVAP vent solenoid controls fresh airflow into the EVAP canister. The solenoid is normally open. The control module will command the solenoid closed during some EVAP tests, allowing the system to be tested for leaks.

Fuel Tank Pressure Sensor

The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. As FTP increases, FTP sensor voltage decreases, high pressure equals low voltage. As FTP decreases, FTP voltage increases, low pressure or vacuum equals high voltage.

EVAP Service Port

The EVAP service port is located in the EVAP purge pipe between the EVAP purge solenoid and the EVAP canister. The service port is identified by a green colored cap.

Electronic Ignition (EI) System Description

The electronic ignition (EI) system is responsible for producing and controlling a high energy secondary spark. This spark is used to ignite the compressed air/fuel mixture at precisely the correct time. This provides optimal performance, fuel economy, and control of exhaust emissions. This ignition system uses one coil for each pair of cylinders. Each pair of cylinders that are at top dead center (TDC) at the same time are known as companion cylinders. The cylinder that is at TDC of the compression stroke is called the event cylinder. The cylinder that is at TDC of the exhaust stroke is called the waste cylinder. When the coil is triggered both companion cylinder spark plugs fire at the same time, completing a series circuit. Because the lower pressure inside the waste cylinder offers very little resistance, the event cylinder uses most of the available voltage to produce a very high energy spark. This is known as waste spark ignition. The EI system consists of the following components

Crankshaft position (CKP) sensors The CKP sensor B is a variable reluctance sensor. The magnetic field of the sensor is altered by a crankshaft mounted reluctor wheel that has seven machined slots, six of which are equally spaced 60 degrees apart. The seventh slot is spaced 10 degrees after one of the 60 degree slots. This sensor provides the ignition control module (ICM) with 7X signals, or seven pulses for each revolution of the crankshaft. The pulse from the 10 degree slot is known as the sync pulse. Both of the sensor circuits are connected to the ignition control module (ICM). A signal converter within the ICM produces digital 3X output pulse to the powertrain control module (PCM), the 3X reference is known as the low resolution engine speed signal. The CKP sensor A contains a hall-effect switch. A hall-effect switch is a solid state switching device that produces a digital ON/OFF pulse when a rotating element passes between the sensor tip and a magnet. This rotating element is called an interrupter ring or blade. In this case the interrupter ring has 24 evenly spaced blades and windows and is part of the crankshaft damper assembly. This sensor provides the PCM with 24X signals, or 24 identical pulses per crankshaft revolution. The 24X signal is used for enhanced smoothness and idle stability at a lower calibrated RPM. The PCM supplies the sensor with a 12-volt reference, low reference, and signal circuit.
Camshaft position (CMP) sensor The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor does not directly affect the operation of the ignition system. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the crankshaft position. By monitoring the CMP and CKP signals the PCM can accurately time the operation of the fuel injectors. The PCM supplies the sensor with a 12-volt reference, low reference, and signal circuit.
Ignition control module (ICM) and ignition coils Three dual tower ignition coils are mounted to the ICM, and are serviced individually. The ICM performs the following functions: The ICM receives and processes the signals from the CKP sensor B. The ICM determines the correct direction of the crankshaft rotation, and cuts spark and fuel delivery to prevent damage from backfiring if reverse rotation is detected. The ICM determines the correct coil triggering sequence, based on the 7X CKP signal. This coil sequencing occurs at start-up, and is remembered by the ICM. After the engine is running, the ICM will continue to trigger the coils in the correct sequence. The ICM produces and inputs 3X reference signals to the PCM. The ICM contains the coil driver circuits that command the coils to operate.
The powertrain control module (PCM) The PCM is responsible for maintaining proper spark and fuel injection timing for all driving conditions. Ignition control (IC) spark timing is the method the PCM uses to control spark advance. To provide optimum driveability and emissions, the PCM monitors input signals from the following components in calculating ignition spark timing: The ignition control module (ICM) The throttle position (TP) sensor The engine coolant temperature (ECT) sensor The mass air flow (MAF) sensor The intake air temperature (IAT) sensor The vehicle speed sensor (VSS) The transmission gear position or range information sensors The engine knock sensors (KS)
The following describes the PCM to ICM circuits: Low resolution engine speed, 3X reference-PCM input-From the ICM, the PCM uses this signal to calculate engine RPM and CKP. The PCM also uses the pulses on this circuit to initiate injector operation. Low reference-PCM input-this is a ground circuit for the digital RPM counter inside the PCM, but the wire is connected to engine ground only through the IC module. This circuit creates a common ground plane and assures there is no ground drop between the PCM and IC module. IC timing signal -PCM output-ICM controls spark timing while the engine is cranking, this is called bypass mode. Once the PCM receives 3X reference signals from the ICM, the PCM applies 5 volts to the IC timing signal circuit allowing the ICM to switch spark advance to PCM control. IC timing control-PCM output-The IC output circuitry of the PCM sends out timing signals to the ICM on this circuit. When in the Bypass Mode, the ICM grounds these signals. When in the IC Mode, the signals are sent to the ICM to control spark timing.
Modes of operation Anytime the PCM does not apply 5 volts to the IC timing signal circuit, the ICM controls ignition by triggering each coil in the proper sequence at a pre-calibrated timing advance. This is called Bypass Mode ignition used during cranking or running below a certain RPM, or during a default mode due to a system failure. When the PCM begins receiving 24X reference and 3X reference pulses, the PCM applies 5 volts to the IC timing signal circuit. This signals the IC module to allow the PCM to control the spark timing. This is IC Mode ignition. During IC Mode, the PCM compensates for all driving conditions. If the IC mode changes due to a system fault, the system will stay in default until the ignition is cycled OFF/ON, or the fault is no longer present. Diagnostic trouble codes are available to accurately diagnose the ignition system with a scan tool.

Purpose

The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock.

Sensor Description

This knock sensor (KS) system uses one or 2 broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependent upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing.

One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters.

Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal.

In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output.

Exhaust Gas Recirculation (EGR) System

The exhaust gas recirculation (EGR) system is used to reduce the amount of nitrogen oxide (NOx) emission levels caused by combustion temperatures exceeding 816°C (1,500°F). It does this by introducing small amounts of exhaust gas back into the combustion chamber. The exhaust gas absorbs a portion of the thermal energy produced by the combustion process and thus decreases combustion temperature. The EGR system will only operate under specific temperature, barometric pressure and engine load conditions in order to prevent drivability concerns and to increase engine performance.

Scheme 103

Scheme 103: Linear EGR Valve

The linear EGR valve consists of the following

The EGR valve position sensor
The EGR valve position sensor cap
The bobbin and coil assembly
The valve pintle
The primary pole piece
The armature sleeve
The armature and base assembly
The exhaust gas inlet port
The exhaust gas outlet port

Linear EGR Control

The linear EGR valve is controlled by a high side driver within the PCM. The high side driver provides 12 volts that is pulse width modulated (PWM) by a duty cycle via the high control circuit of the EGR valve. The ground path is provided by the low control circuit of the EGR valve. The PCM calculates the amount of EGR needed based on the following inputs

The engine coolant temperature (ECT) sensor
The intake air temperature (IAT) sensor
The barometric pressure (BARO)
The manifold absolute pressure (MAP) sensor
The throttle position (TP) sensor
The mass air flow (MAF) sensor

EGR Diagnostics

The PCM tests the EGR flow during deceleration by momentarily commanding the EGR valve to open while monitoring the signal of the manifold absolute pressure (MAP) sensor. When the EGR valve is opened, the PCM will expect to see a predetermined increase in MAP. If the expected increase in MAP is not detected, the PCM records the amount of MAP difference that was detected and adjusts a calibrated fail counter towards a calibrated fail threshold level. When the fail counter exceeds the fail threshold level, the PCM will set a diagnostic trouble code (DTC).

Normally, the PCM will only allow one EGR Flow Test Count during an ignition cycle. To aid in verifying a repair, the PCM allows twelve EGR Flow Test Counts during the first ignition cycle following a code clear or a battery disconnect. Between nine and twelve EGR Flow Test Counts should be sufficient for the PCM to determine adequate EGR flow and pass the EGR flow test. If the PCM detects an EGR flow error, a DTC will set.

The PCM monitors the position of the EGR valve pintle via the EGR position sensor. If the PCM detects a calibrated variance between the Desired EGR Position parameter and the EGR Position Sensor parameter, actual position, for a calibrated amount of time a DTC will set.

The PCM also monitors the EGR solenoid high control circuit EGR solenoid low control circuit for electrical faults. If an EGR control circuit fault is detected for a calibrated amount of time a DTC will set.

Air Intake System Description

The primary function of the air intake system is to provide filtered air to the engine. The system uses a cleaner element mounted in a housing. The cleaner housing is remotely mounted and uses intake ducts to route the incoming air into the throttle body. The secondary function of the air intake system is to muffle air induction noise. This is achieved through the use of resonators molded into the air cleaner housing. The resonators are tuned to the specific powertrain. The mass air flow (MAF) sensor is used to measure the air entering the engine.

Special Tools

Special Tools Illustration Part Number/Description J 23738-A Mityvac J 26792 Spark Tester J 33431-B Signal Generator J 34142-B Test Lamp J 34730-1A Fuel Pressure Gage J 34730-262 Fuel Pressure Gage Fitting J 35616-A Connector Test Adapter Kit J 35800 Fuel Injector Cleaner J 37027-1A IAC Motor Driver You may also use an IAC Motor Driver from one of the approved manufacturers listed below: OTC Thexton CTI Snap On MAC Tools NAPA/Balkamp J 37088-A Fuel Line Disconnect Tool Set J 37287 Fuel Line Shut-off Adapters J 385000 Fuel Injector Cleaner J 39021 Fuel Injector Coil/Balance Tester J 39021-210 Injector Tester Adapter Box J 39021-410 Fuel Injector Test Harness J 39194-B Heated Oxygen Sensor Wrench J 39200 Digital Multimeter (DMM) J 39765 Fuel Sender Lock Nut Wrench J 41413-200 Evaporative Emissions System Tester (EEST) J 41413-VLV EVAP Service Port Vent Fitting J 41413-SPT High Intensity White Light J 41415-40 Fuel Tank Cap Adapter J 41416 Ultrasonic Leak Detector J 42598 Vehicle Data Recorder J 42873-1 3/8 Fuel Line Shut-Off Valve J 42873-2 5/16 Return Pipe Shut-Off Valve J 42960-2 Fuel Flapper Door Handle J 42964-1 3/8 Fuel Line Shut-Off Valve J 42964-2 5/16 Fuel Line Shut-Off Valve J 43244 Relay Puller Pliers J 44175 Fuel Composition Tester J 45004 Fuel Tank Drain Hose 7000081 Tech 2 Diagnostic Scan Tool