Engine Controls and Fuel - 3.6L - Introduction: Removal & Installation Cadillac STS I facelift

Engine Control Module Replacement

Note. It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5000 km (3,000 mi) from the last engine oil change.

Note. It is necessary to record the remaining automatic transmission fluid life. If the replacement module is not programed with the remaining automatic transmission fluid life, the automatic transmission fluid life will default to 100 percent. If the replacement module is not programmed with the remaining automatic transmission fluid life, the automatic transmission fluid will need to be changed at 83000 km (50,000 mi) from the last automatic transmission fluid change.

Removal Procedure

1. Using a scan tool, retrieve the percentage of remaining engine oil and automatic transmission fluid life. Record the remaining engine oil and automatic transmission fluid life.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (Side Post)»(ref-338135-S42862392442009081700000) .
3. Unlock and disconnect the engine wiring harness electrical connectors (1) from the ECM (2).
4. Use the tabs (3) in order to disengage the retainers (2) on the ECM bracket from the ECM (1) and remove the ECM.
5. If replacing the ECM bracket perform the following steps, otherwise proceed to step 4 in the installation procedure.
6. Using a small flat-bladed tool, depress the locking tabs (1) on the ECM bracket.
7. Slide up and remove the ECM bracket (1).

Installation Procedure

1. If replacing the ECM bracket perform the following steps, other wise proceed to step 4.
2. Slide down and install the ECM bracket (1).
3. Ensure that the ECM bracket engages the locking tabs (1).
4. Slide the ECM (1) into the ECM bracket, ensure that the ECM engages the bracket retainers (2).
5. Connect and lock the engine wiring harness electrical connectors (1) to the ECM (2).
6. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (Side Post)»(ref-338135-S42862392442009081700000) .
7. Program the ECM, if required. Refer to «Control Module References»(ref-338152-S12253781062009081700000) .
8. Turn OFF the ignition for a least 5 seconds after the programming event is complete.

1. Turn the ignition OFF.
2. Remove the engine oil dipstick indicator.
3. Slide the electrical connector heat protector (1) off the electrical connector.
4. Disconnect the coolant temperature sensor electrical connector.
5. Remove the coolant temperature sensor.

1. Install the coolant temperature sensor and tighten to 22 N.m (16 lb ft).
2. Install the coolant temperature sensor electrical connector.
3. Slide the electrical connector heat protector (1) onto the electrical connector.
4. Inspect and fill the cooling system as necessary. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

Scheme 19

1. Turn the ignition OFF.
2. Remove the fuel injector sight shield, if necessary. Refer to «Fuel Injector Sight Shield Replacement (LLT)»(ref-338138-S06537109962009081700000) .
3. Disconnect the heated oxygen sensor (HO2S) electrical connector.
4. Remove the HO2S electrical connector from the wiring harness bracket.
5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
6. Remove the HO2S from the catalytic converter.

1. Install the HO2S to the catalytic converterand tighten to 40 N.m (30 lb ft).
2. Lower the vehicle.
3. Install the HO2S electrical connector to the wiring harness bracket.
4. Connect the HO2S electrical connector.
5. Install the fuel injector sight shield, if necessary. Refer to «Fuel Injector Sight Shield Replacement (LLT)»(ref-338138-S06537109962009081700000) .

1. Turn the ignition OFF.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
3. Disconnect the heated oxygen sensor (HO2S) electrical connector.
4. Remove the HO2S wiring harness from the transmission case.
5. Remove the HO2S.

1. Install the HO2S and tighten to 40 N.m (30 lb ft).
2. Connect the HO2S electrical connector.
3. Install the HO2S wiring harness to the transmission case.
4. Lower the vehicle.

1. Turn the ignition OFF.
2. Remove the fuel injector sight shield, if necessary. Refer to «Fuel Injector Sight Shield Replacement (LLT)»(ref-338138-S06537109962009081700000) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
4. Disconnect the heated oxygen sensor (HO2S) electrical connector.
5. Remove the HO2S electrical connector from the wiring harness bracket.
6. Remove the HO2S.

1. Install the HO2S and tighten to 40 N.m (30 lb ft).
2. Install the HO2S electrical connector to the wiring harness bracket.
3. Connect the HO2S electrical connector.
4. Lower the vehicle.
5. Install the fuel injector sight shield, if necessary. Refer to «Fuel Injector Sight Shield Replacement (LLT)»(ref-338138-S06537109962009081700000) .

1. Turn the ignition OFF.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
3. Disconnect the heated oxygen sensor (HO2S) electrical connector.
4. Remove the HO2S wiring harness from the transmission case.
5. Remove the HO2S.

1. Install the HO2S and tighten to 40 N.m (30 lb ft).
2. Connect the HO2S electrical connector.
3. Install the HO2S wiring harness to the transmission case.
4. Lower the vehicle.

1. Remove the closeout/insulator panel from under the dashboard on the drivers side. Refer to «Instrument Panel Insulator Panel Replacement - Left Side»(ref-338119-S20980418342009081700000) or «Instrument Panel Insulator Panel Replacement - Right Side»(ref-338119-S20896233922009081700000) .
2. Disconnect the accelerator pedal position (APP) sensor electrical connector from the accelerator pedal module.
3. Remove the nuts from the APP sensor and remove the APP sensor from the front of dash.

1. Install the APP sensor to the front of dash.
2. Install the APP sensor mounting nuts and tighten to 9 N.m (80 lb in).
3. Connect the APP sensor electrical connector.
4. Operate the accelerator pedal and observe the APP angles using a scan tool. The accelerator pedal should operate freely, without binding between closed throttle and wide open throttle.
5. Install the closeout/insulator panel. Refer to «Instrument Panel Insulator Panel Replacement - Left Side»(ref-338119-S20980418342009081700000) or «Instrument Panel Insulator Panel Replacement - Right Side»(ref-338119-S20896233922009081700000) .

1. Turn the ignition OFF.
2. Remove the air cleaner intake duct. Refer to «Air Cleaner Inlet Duct Replacement»(ref-338169-S06455195582009081700000) .
3. Remove the throttle body electrical connector.
4. Unlock and reposition the wiring harness conduit.
5. Remove the throttle body bolts.
6. Remove the throttle body and gasket.

1. Carefully clean the throttle body mounting surfaces of any gasket and/or seal material.
2. Install the throttle body and NEW gasket.
3. Install the throttle body bolts and tighten to 10 N.m (89 lb in).
4. Install the wiring harness conduit.
5. Install the throttle body electrical connector.
6. Install the air cleaner intake duct. Refer to «Air Cleaner Inlet Duct Replacement»(ref-338169-S06455195582009081700000) .
7. Perform the throttle learn procedure. Refer to «Throttle Learn»(ref-338169-S19539185092009081700000) .
8. Use the scan tool to clear all DTCs.

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (With High Pressure Pump - LLT)»(ref-338169-S29520756722009081700000) .
2. Connect the CH-48027-1 (1) to the CH-48027-2 (2).
3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's directions. See «Special Tools»(ref-338169-S23212902312009081700000) .

1. Relieve the fuel system pressure, if required. Perform the following steps: WARNING: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. Wrap a shop towel around the fuel rail service port. Place the hose on the CH-48027-2 (2) into an approved gasoline container. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. Close the valve on the CH-48027-2 (2). Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
4. Disconnect the CH-48027-3 (4) from the fuel rail service port.
5. Install the fuel rail service port cap.
6. Tighten the fuel fill cap.

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (With High Pressure Pump - LLT)»(ref-338169-S29520756722009081700000) .
2. Remove the retainer from the quick-connect fitting.
3. Blow dirt out of the fitting using compressed air.
4. Depending on the fuel line size and ability to access the fitting, choose the appropriate tool: J 37088-A or J 44581 . See «Special Tools»(ref-338169-S23212902312009081700000) . Insert the J 37088-A or J 44581 into the female connector, then push inward to release the locking tabs. See «Special Tools»(ref-338169-S23212902312009081700000) .
5. Pull the connection apart.
6. Using a clean shop towel, wipe off the male pipe end.
7. Inspect both ends of the fitting for dirt and burrs.
8. Clean or replace the components as required.

1. Apply a few drops of clean engine oil to the male pipe end.
2. Push both sides of the quick-connect fitting together to cause the retaining tabs to snap into place.
3. Pull on both sides of the quick-connect fitting to make sure the connection is secure.
4. Install the retainer to the quick-connect fitting.
5. Inspect for leaks using the following procedure: Turn the ignition ON, with the engine OFF for 2 seconds. Turn the ignition OFF, for 10 seconds. Turn the ignition ON, with the engine OFF for 2 seconds. Turn the ignition OFF. Inspect for leaks.

1. Keep a shop cloth and a container ready to capture any spilled fuel.
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (With High Pressure Pump - LLT)»(ref-338169-S29520756722009081700000) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
4. Remove the rear suspension bracket. Refer to «Rear Suspension Bracket Replacement»(ref-338143-S12039122612009081700000) .
5. Disconnect the quick-connect fitting at the fuel filter inlet. Refer to «Metal Collar Quick Connect Fitting Service»(ref-338169-S19593842732009081700000) .
6. Using a primary and back-up wrench, remove the threaded fitting at the fuel filter outlet.
7. Slide the fuel filter rearward from the fuel filter bracket.
8. Remove the fuel pipe O-ring seal. Discard the O-ring seal if damaged.
9. Drain any remaining fuel into an approved gasoline container.
10. Discard the fuel filter into an approved container.

1. Lubricate the fuel pipe O-ring seal with clean engine oil.
2. Install the fuel pipe O-ring seal to the fuel pipe.
3. Remove the protective caps from the new fuel filter.
4. Slide the fuel filter forward into the fuel filter bracket.
5. Install the threaded fitting to the fuel filter outlet. Use a back-up wrench in order to prevent the fuel filter from turning and tighten to 30 N.m (22 lb ft).
6. Connect the quick-connect fitting at the fuel filter inlet. Refer to «Metal Collar Quick Connect Fitting Service»(ref-338169-S19593842732009081700000) .
7. Install the rear suspension bracket. Refer to «Rear Suspension Bracket Replacement»(ref-338143-S12039122612009081700000) .
8. Lower the vehicle.

1. Drain the fuel tank. Refer to «Fuel Tank Draining»(ref-338169-S28441476142009081700000) .
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (With High Pressure Pump - LLT)»(ref-338169-S29520756722009081700000) .
3. Remove the exhaust system. Refer to «Exhaust System Replacement»(ref-338131-S05393811512009081700000) .
4. Remove the rear propeller shaft. Refer to «Rear Propeller Shaft Replacement (AWD)»(ref-338144-S22580991792009081700000) or «Rear Propeller Shaft Replacement (RWD)»(ref-338144-S39823555952009081700000) .
5. Remove the rear frame assembly (2). Refer to «Rear Frame Replacement»(ref-338127-S05016546182009081700000) .
6. Disconnect the filler hose (1) from the fuel tank.
7. Disconnect the filler vent tube (2) from the evaporative emission (EVAP) hose. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-338169-S39416836252009081700000) .
8. Disconnect the fuel feed pipe (1) from the chassis bundle. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-338169-S39416836252009081700000) .
9. Disconnect the fuel EVAP hose (2) from the chassis bundle. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-338169-S39416836252009081700000) .
10. Release the electrical connector interlock and disconnect the fuel tank electrical connector.
11. Remove the fuel tank electrical connector retainer from the chassis.
12. Remove the fuel tank electrical harness from the chassis mounted retainer.
13. Disconnect the EVAP hoses from the EVAP canister.
14. Pull outward on the retainer tab in order to disengage the retainer from the chassis.
15. Disconnect the electrical connector from the fuel tank pressure sensor (1).
16. Disconnect the electrical connector from the EVAP canister vent valve.
17. Support the fuel tank with a suitable jack.
18. Remove the fuel tank strap bolts.
19. Remove the fuel tank straps.
20. With the aid of an assistant, carefully lower the fuel tank from the vehicle.
21. Remove the following components if replacing just the fuel tank: The primary fuel tank module-Refer to «Primary Fuel Tank Module Replacement»(ref-338169-S20811326332009081700000) . The secondary fuel tank module-Refer to «Secondary Fuel Tank Module Replacement»(ref-338169-S39726042822009081700000) .

1. Install the following components if fuel tank replacement was necessary: The primary fuel tank module-Refer to «Primary Fuel Tank Module Replacement»(ref-338169-S20811326332009081700000) . The secondary fuel tank module-Refer to «Secondary Fuel Tank Module Replacement»(ref-338169-S39726042822009081700000) .
2. With the aid of an assistant, carefully raise the fuel tank to the vehicle.
3. Install the fuel tank straps to the vehicle.
4. Install the fuel tank strap bolts and tighten to 50 N.m (37 lb ft).
5. Connect the filler hose (1) to the fuel tank and tighten to 3.5 N.m (31 lb in).
6. Connect the filler vent tube (2) to the EVAP hose. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-338169-S39416836252009081700000) .
7. Connect the EVAP hoses to the EVAP canister.
8. Connect the EVAP purge valve and fuel tank pressure sensor electrical connectors.
9. Install the fuel tank wire harness and wire harness connector to the retainers on the chassis.
10. Connect the fuel tank electrical connector, and engage the connector interlock.
11. Connect the fuel EVAP hose (2) to the chassis bundle. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-338169-S39416836252009081700000) .
12. Connect the fuel feed pipe (1) to the chassis bundle. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-338169-S39416836252009081700000) .
13. Install the rear frame assembly (2). Refer to «Rear Frame Replacement»(ref-338127-S05016546182009081700000) .
14. Install the propeller shaft. Refer to «Rear Propeller Shaft Replacement (AWD)»(ref-338144-S22580991792009081700000) or «Rear Propeller Shaft Replacement (RWD)»(ref-338144-S39823555952009081700000) .
15. Install the exhaust system. Refer to «Exhaust System Replacement»(ref-338131-S05393811512009081700000) .
16. Refill the fuel tank.
17. Inspect for fuel leaks.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
2. Disconnect the fuel tank pressure sensor electrical connector (1).
3. Remove the fuel tank pressure sensor from the evaporative emission (EVAP) canister.

1. Install the fuel tank pressure sensor to the EVAP canister until fully seated.
2. Connect the fuel tank pressure sensor electrical connector (1).
3. Lower the vehicle.

1. Remove the fuel filler cap.
2. Drain the fuel tank below the level of the fuel filler hose. Refer to «Fuel Tank Draining»(ref-338169-S28441476142009081700000) .
3. Remove the bolts securing the fuel filler tube to the body.
4. Remove the right rear wheel. Refer to «Tire and Wheel Removal and Installation»(ref-338140-S19340800482009081700000) .
5. Remove the right rear wheelhouse liner. Refer to «Rear Wheelhouse Panel Liner Replacement»(ref-338127-S08500977682009081700000) .
6. Remove the fuel filler tube brace bolt.
7. Disconnect the fuel filler hose (1) from the fuel tank.
8. Disconnect the filler vent tube (2) from the evaporative emission (EVAP) hose. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-338169-S39416836252009081700000) .
9. Remove the fuel filler tube from the vehicle.

1. Position the fuel filler tube to the vehicle.
2. Connect the filler hose (1) to the fuel tank and tighten to 3.5 N.m (31 lb in).
3. Connect the filler vent tube (2) to the EVAP hose. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-338169-S39416836252009081700000) .
4. Install the fuel filler tube brace bolt and tighten to 9 N.m (80 lb in).
5. Install the bolts securing the fuel filler tube to the body and tighten to 3.5 N.m (31 lb in).
6. Install the right rear wheelhouse liner. Refer to «Rear Wheelhouse Panel Liner Replacement»(ref-338127-S08500977682009081700000) .
7. Install the right rear wheel. Refer to «Tire and Wheel Removal and Installation»(ref-338140-S19340800482009081700000) .
8. Add fuel to the fuel tank.
9. Inspect for fuel leaks.
10. Install the fuel filler cap.

1. Remove the fuel tank in order to gain access to the primary fuel tank module (1). Refer to «Fuel Tank Replacement»(ref-338169-S07606469012009081700000) .
2. Disconnect the fuel feed hose quick connect fitting (4) from the primary fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-338169-S39416836252009081700000) .
3. Remove the fuel feed hose (2) from the retainer on the fuel tank and position the hose aside.
4. Release the interlock and disconnect the electrical connector (3) from the primary fuel tank module.
5. Remove the wire harness (1) from the retainer on the fuel tank and position the harness aside.
6. Use the J 45722 (2) and a long breaker-bar (1) in order to unlock the fuel tank module lock ring (3), by turning counterclockwise.
7. Remove the cam lock ring.
8. Partially remove the primary fuel tank module (1) in order to gain access to the fuel transfer hose quick connect fitting (3). Use care not to damage the float arm (2).
9. Disconnect the fuel transfer hose quick connect fitting (3).
10. Remove the primary fuel tank module from the fuel tank.
11. Discard the fuel tank module seal (4).
12. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points.
13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

1. Install a NEW fuel tank module seal (4).
2. Grasp the fuel transfer hose from inside the fuel tank.
3. Partially install the primary fuel tank module (1) to the fuel tank.
4. Connect the fuel transfer hose quick connect fitting (3) to the port on the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-338169-S39416836252009081700000) .
5. Press the primary fuel tank module downward, aligning the module to the encapsulated ring.
6. Position the cam lock ring (3) to the fuel tank.
7. Use the J 45722 (2) and a long breaker-bar (1) to install the fuel tank module lock ring (3), by turning clockwise, until fully seated.
8. Connect the electrical connector (3) to the primary fuel tank module and engage the connector interlock.
9. Install the wire harness (1) to the retainer on the fuel tank.
10. Connect the fuel feed hose quick connect fitting (4) to the primary fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-338169-S39416836252009081700000) .
11. Install the fuel feed hose (2) to the retainer on the fuel tank.
12. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-338169-S07606469012009081700000) .

1. Remove the fuel tank in order to gain access to the secondary fuel tank module (2). Refer to «Fuel Tank Replacement»(ref-338169-S07606469012009081700000) .
2. Release the interlock and disconnect the electrical connector (1) from the secondary fuel tank module. Position the connector and wire harness aside.
3. Use the J 45747 (1) and a long breaker-bar (2) in order to unlock the fuel tank module lock ring (3), by turning counterclockwise. See «Special Tools»(ref-338169-S23212902312009081700000) .
4. Remove the cam lock ring.
5. Partially remove the secondary fuel tank module (2) in order to gain access to the fuel transfer hose quick connect fitting (1). Use care not to damage the float arm (3).
6. Disconnect the fuel transfer hose quick connect fitting (1).
7. Remove the secondary fuel tank module from the fuel tank.
8. Discard the fuel tank module seal (4).
9. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points.
10. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
11. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

1. Install a NEW fuel tank module seal (4).
2. Grasp the fuel transfer hose from inside the fuel tank.
3. Partially install the secondary fuel tank module (2) to the fuel tank.
4. Connect the fuel transfer hose quick connect fitting (1) to the port on the fuel tank module.
5. Press the secondary fuel tank module downward, aligning the module to the encapsulated ring.
6. Position the cam lock ring (3) to the fuel tank.
7. Use the J 45747 (1) and a long breaker-bar (2) to install the fuel tank module lock ring (3), by turning clockwise, until fully seated. See «Special Tools»(ref-338169-S23212902312009081700000) .
8. Connect the electrical connector (1) to the secondary fuel tank module and engage the connector interlock.
9. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-338169-S07606469012009081700000) .

1. Remove the primary fuel tank module. Refer to «Primary Fuel Tank Module Replacement»(ref-338169-S20811326332009081700000) .
2. Disconnect the fuel level sensor electrical connector (1) from the module.
3. Complete the following in order to remove the fuel level sensor (1) from the module assembly: Pull the locking tab (2) away from the sensor (1). Slide the sensor (1) away from the module assembly.

1. Complete the following in order to install the fuel level sensor (1) to the module assembly: Align the tabs of the sensor (1) with the slots in the module assembly. Slide the sensor (1) fully into position, ensure the locking tab (2) is engaged.
2. Connect the fuel level sensor electrical connector (1) to the module.
3. Install the primary fuel tank module. Refer to «Primary Fuel Tank Module Replacement»(ref-338169-S20811326332009081700000) .

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-338169-S07606469012009081700000) .
2. Disconnect the fuel lines from the primary fuel tank module. Refer to «Metal Collar Quick Connect Fitting Service»(ref-338169-S19593842732009081700000) and «Plastic Collar Quick Connect Fitting Service»(ref-338169-S39416836252009081700000) .
3. Disconnect the hoses from the retaining feature at the fuel tank.

1. Clean any contamination from the male pipe ends of the primary fuel tank module.
2. Connect the hoses to the retaining feature at the fuel tank.
3. Connect the fuel lines from the primary fuel tank module. Refer to «Metal Collar Quick Connect Fitting Service»(ref-338169-S19593842732009081700000) and «Plastic Collar Quick Connect Fitting Service»(ref-338169-S39416836252009081700000) .
4. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-338169-S07606469012009081700000) .

The fuel system hose/pipes are serviceable individually or as a complete fuel/brake bundle assembly, the following procedure is servicing the fuel hose/pipes individually.

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (With High Pressure Pump - LLT)»(ref-338169-S29520756722009081700000) .
2. Remove the fuel pipe retaining clip from the fuel pipe. Refer to «Metal Collar Quick Connect Fitting Service»(ref-338169-S19593842732009081700000) .
3. Disconnect the fuel pipe (2) from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-338169-S19593842732009081700000) .
4. Disconnect the evaporative emission (EVAP) purge line (3) from the purge solenoid.
5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
6. Disconnect the fuel pipes from the fuel filter and the fuel tank bundle.
7. Pull the locking mechanism (1) outward in order to disengage the fuel/brake bundle chassis pipe retainers from the rail.
8. Open the retainers (1) located at the forward portion of the rail in order to remove the chassis hose/pipes.
9. Complete the following in order to remove the chassis hose/pipes from the retainers (2) located at the rearward portion of the rail. Pull the retainers (2) free from the rail. Open the retainers (2) at the top. Remove the chassis hose/pipes from the retainers (2).
10. Pull downward in order to disconnect the fuel/brake bundle chassis pipe retainer from the underbody.
11. Remove the bolt securing the fuel filter bracket to the body.
12. Remove the EVAP hose from the fuel filter bracket.
13. Remove the bolts securing the transmission support to the underbody, from the right side only.
14. Pull the right side transmission support down only enough to allow removal of the chassis fuel hose/pipes.
15. Partially lower the hoist only enough to simultaneously gain access to both the front and rear portions of the chassis fuel hose/pipes.
16. With the aid of an assistant, carefully guide the chassis fuel hose/pipes down through the engine compartment, removing from the bottom.

1. Clean any of the contamination from the male line ends and apply a few drops of clean engine oil.
2. With the aid of an assistant, carefully guide the chassis fuel hose/pipes up through the engine compartment into position.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
4. Pull the right side transmission support down only enough to allow installation of the chassis fuel hose/pipes.
5. Install the transmission support right side bolts. Refer to «Transmission Support Replacement»(ref-338127-S15913290422009081700000) .
6. Install the EVAP hose to the fuel filter bracket
7. Install the fuel filter bracket bolt and tighten to 9 N.m (80 lb in).
8. Install the fuel/brake bundle to the underbody.
9. Complete the following in order to install the chassis hose/pipes to the retainers (2) located at the rearward portion of the rail: Install the chassis hose/pipes into the retainers (2). Close the retainers (2) at the top. Insert the retainers (2) into the rail.
10. Install the chassis hose/pipes into the retainers (1) located at the forward portion of the rail.
11. Close the retainers.
12. Push the locking mechanism (1) inward in order to engage the fuel/brake bundle chassis pipe retainers to the rail.
13. Connect the fuel feed pipe and the EVAP hose to the fuel bundle.
14. Lower the vehicle.
15. Connect the evaporative emission (EVAP) purge line (3) to the purge solenoid.
16. Connect the fuel feed pipe (1) to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-338169-S19593842732009081700000) .
17. Install the fuel pipe retaining clip.

1. Remove the fuel injection sight shield. Refer to «Fuel Injector Sight Shield Replacement (LLT)»(ref-338138-S06537109962009081700000) .
2. Remove the high pressure pump shield. Refer to «Fuel Pipe Shield Replacement (LLT)»(ref-338169-S21766103372009081700000) .
3. Relieve the low side fuel system pressure. Refer to «Fuel Pressure Relief (With High Pressure Pump - LLT)»(ref-338169-S29520756722009081700000) .
4. Remove the radiator surge tank outlet pipe.
5. Disconnect the fuel feed line quick connect fitting from the fuel feed pipe (2). Refer to «Metal Collar Quick Connect Fitting Service»(ref-338169-S19593842732009081700000) .
6. Loosen the fuel feed pipe fitting to the high pressure fuel pump.
7. Remove the fuel feed pipe bolts (4) from the cylinder heads.
8. Remove the fuel feed pipe from the engine and high pressure fuel pump.

1. Ensure that the fuel feed pipe and fuel pump fittings are clean and dry prior to assembly.
2. Position the fuel feed pipe (2) to the cylinder head and high pressure fuel pump.
3. Install the fuel feed pipe fitting to the high pressure fuel pump hand tight.
4. Install the fuel feed pipe bolts (4). Tighten: Tighten the bolts to 50 N.m (37 lb ft). Tighten the fitting to 28 N.m (20 lb ft).
5. Connect the fuel feed line quick connect fitting to the fuel feed pipe (2). Refer to «Fuel Pipe Shield Replacement (LLT)»(ref-338169-S21766103372009081700000) .
6. Inspect for leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
7. Install the low side fuel pressure service port cap.
8. Install the fuel tank cap.
9. Install the radiator surge tank outlet pipe.
10. Install the high pressure pump shield. Refer to «Fuel Pipe Shield Replacement (LLT)»(ref-338169-S21766103372009081700000) .
11. Install the fuel injection sight shield. Refer to «Fuel Injector Sight Shield Replacement (LLT)»(ref-338138-S06537109962009081700000) .

Assemble the fuel system as follows

1. Install the fuel injectors and fuel rail.
2. Install the fuel module assemblies. Refer to «Primary Fuel Tank Module Replacement»(ref-338169-S20811326332009081700000) and «Secondary Fuel Tank Module Replacement»(ref-338169-S39726042822009081700000) .
3. Refer to «Metal Collar Quick Connect Fitting Service»(ref-338169-S19593842732009081700000) in order to connect the following quick connect fittings to the fuel rail: The feed hose/pipe The return hose/pipe

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (With High Pressure Pump - LLT)»(ref-338169-S29520756722009081700000) .
2. Remove the cross vehicle brace. Refer to «Cross Vehicle Brace Replacement»(ref-338113-S17625406482009081700000) .
3. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-338138-S38398417812009081700000) .
4. Remove the foam insulator from the fuel rails.
5. Using a 27 mm socket, remove the fuel pressure sensor (1) from the fuel injection fuel rail (2). Discard the fuel pressure sensor.
6. Allow any fuel to drain from the fuel rail and pressure sensor location.
7. Dry the sealing cone in the fuel rail and the area around the sensor joint with a lint free cloth.
8. Inspect the sealing cone in the fuel rail. The surface should be free of fuel, debris, and burrs.

Note. Applying force to the plastic housing of the sensor will destroy the sensor. To tighten or loosen, only apply force to the attached hexagon.

Note. Ensure that the fuel rail threads have been cleaned of any excess fuel, or the NEW fuel injection fuel rail fuel pressure sensor will NOT seal properly.

1. Lubricate the threads and the sealing cone in the fuel rail with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
2. Lubricate the threads and sealing cone on the NEW fuel injection fuel rail fuel pressure sensor with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
3. Install the NEW fuel pressure sensor (1) to the fuel injection fuel rail (2) hand tight.
4. Remove the NEW fuel injection fuel rail fuel pressure sensor, re-lubricate following steps 1 and 2 above.
5. Install the NEW fuel pressure sensor (1) to the fuel injection fuel rail (2). Tighten: Tighten the sensor to 33 N.m (25 lb ft).
6. Install the foam insulator from the fuel rails.
7. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-338138-S38398417812009081700000) .
8. Inspect for fuel leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
9. Install the cross vehicle brace. Refer to «Cross Vehicle Brace Replacement»(ref-338113-S17625406482009081700000) .

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (With High Pressure Pump - LLT)»(ref-338169-S29520756722009081700000) .
2. Remove the cross vehicle brace. Refer to «Cross Vehicle Brace Replacement»(ref-338113-S17625406482009081700000) .
3. Remove the fuel pipe shield. Refer to «Fuel Pipe Shield Replacement (LLT)»(ref-338169-S21766103372009081700000) .
4. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-338138-S38398417812009081700000) .
5. Remove the high pressure fuel pipe. Discard the pipe. Refer to «Fuel Feed Intermediate Pipe Replacement (LLT)»(ref-338169-S14101054272009081700000) .
6. Remove the fuel rail crossover pipe. Refer to «Fuel Injection Fuel Rail Crossover Tube Replacement (LLT)»(ref-338169-S16165300882009081700000) . Discard the pipe.
7. Remove the foam insulator from the fuel rails.
8. Disconnect the fuel pressure sensor electrical connector and cut the wire harness tie straps.
9. Remove the fuel rail (2) bolts (1).
10. Remove the fuel pressure sensor. Refer to «Fuel Pressure Sensor Replacement (LLT)»(ref-338169-S14111109312009081700000) .
11. Remove and discard the direct fuel injector hold down clamps.
12. Once the fuel rail is removed, remove the fuel injectors and rebuild them. Refer to «Fuel Injector Replacement (LLT)»(ref-338169-S29595471272009081700000) .

1. Install the rebuilt direct fuel injectors (1) to the cylinder heads. Refer to «Fuel Injector Replacement (LLT)»(ref-338169-S29595471272009081700000) .
2. Install NEW direct injector hold down clamps to the injector.
3. On a new fuel rail, lubricate the fuel injector cups with silicon free engine oil GM P/N 12345610 (Canadian P/N 9931930) or equivalent.
4. Carefully place the fuel rail (2) into position, placing the front into the fuel rail over the front injector and rotating the rear downward.
5. Install the 2 outer fuel rail bolts first, then the 2 inner bolts, and hand tighten.
6. Tighten the fuel rail bolts in the sequence shown: Tighten: Tighten the Bank 1 fuel rail bolts first pass to 12 N.m (106 lb in). Tighten the Bank 1 fuel rail bolts final pass to 23 N.m (17 lb ft).
7. Install a NEW fuel rail crossover pipe. Refer to «Fuel Injection Fuel Rail Crossover Tube Replacement (LLT)»(ref-338169-S16165300882009081700000) .
8. Install a NEW high pressure fuel pipe. Refer to «Fuel Feed Intermediate Pipe Replacement (LLT)»(ref-338169-S14101054272009081700000) .
9. Install the high pressure fuel sensor (1). Refer to «Fuel Pressure Sensor Replacement (LLT)»(ref-338169-S14111109312009081700000) .
10. Connect the fuel injector wiring harness electrical connector (1) to the fuel injectors, fuel rail and fuel pressure sensor.
11. Inspect for fuel leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
12. Install the foam insulator from the fuel rails.
13. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-338138-S38398417812009081700000) .
14. Install the fuel pipe shield. Refer to «Fuel Pipe Shield Replacement (LLT)»(ref-338169-S21766103372009081700000) .
15. Install the low side fuel pressure service port cap.
16. Install the fuel tank cap.
17. Install the cross vehicle brace. Refer to «Cross Vehicle Brace Replacement»(ref-338113-S17625406482009081700000) .

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (With High Pressure Pump - LLT)»(ref-338169-S29520756722009081700000) .
2. Remove the fuel pipe shield. Refer to «Fuel Pipe Shield Replacement (LLT)»(ref-338169-S21766103372009081700000) .
3. Remove the high pressure fuel sensor. Refer to «Fuel Pressure Sensor Replacement (LLT)»(ref-338169-S14111109312009081700000) .
4. Remove the fuel rail crossover pipe. Refer to «Fuel Injection Fuel Rail Crossover Tube Replacement (LLT)»(ref-338169-S16165300882009081700000) . Discard this pipe.
5. Remove the fuel rail bolts (1).
6. Carefully remove the Bank 2 fuel rail (2) from the engine. Lift the rear of the rail to ease removal.
7. Remove and discard the direct fuel injector hold down clamps.
8. Once the fuel rail is removed, remove the fuel injectors and rebuild them. Refer to «Fuel Injector Replacement (LLT)»(ref-338169-S29595471272009081700000) .

1. Install the rebuilt direct fuel injectors (1) to the cylinder heads. Refer to «Fuel Injector Replacement (LLT)»(ref-338169-S29595471272009081700000) .
2. Install new direct injector hold down clamps to the injectors.
3. On the new fuel rail, lubricate the fuel injector cups with silicon free engine oil GM P/N 12345610 (Canadian P/N 9931930) or equivalent.
4. Carefully place the fuel rail (2) into position, placing the front into the fuel rail over the front injector and rotating the rear downward.
5. Install the 2 outer fuel rail bolts first, then the 2 inner bolts and hand tighten.
6. Tighten the fuel rail bolts in the sequence shown: Tighten: Tighten the Bank 1 fuel rail bolts first pass to 12 N.m (106 lb in). Tighten the Bank 1 fuel rail bolts a final pass to 23 N.m (17 lb ft).
7. Install a NEW fuel rail crossover pipe. Refer to «Fuel Injection Fuel Rail Crossover Tube Replacement (LLT)»(ref-338169-S16165300882009081700000) .
8. Install the high pressure fuel sensor. Refer to «Fuel Pressure Sensor Replacement (LLT)»(ref-338169-S14111109312009081700000) .
9. Connect the fuel injector wiring harness electrical connector (1) from the fuel injectors, fuel rail and fuel pressure sensor.
10. Inspect for fuel leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
11. Install the fuel pipe shield. Refer to «Fuel Pipe Shield Replacement (LLT)»(ref-338169-S21766103372009081700000) .
12. Install the low side fuel pressure service port cap.
13. Install the fuel tank cap.

1. Remove the fuel injection sight shield. Refer to «Fuel Injector Sight Shield Replacement (LLT)»(ref-338138-S06537109962009081700000) .
2. Remove the high pressure pump shield. Refer to «Fuel Pipe Shield Replacement (LLT)»(ref-338169-S21766103372009081700000) .
3. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (With High Pressure Pump - LLT)»(ref-338169-S29520756722009081700000) .
4. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-338138-S38398417812009081700000) .
5. Loosen the fuel rail crossover pipe (1) fitting to the right fuel rail (2).
6. Loosen the fuel rail crossover pipe (1) fitting to the right fuel rail (3).
7. Remove the fuel rail crossover pipe (1) from the vehicle. Discard the pipe.

1. Ensure that the fuel rail crossover pipe, right fuel rails fittings and left fuel rail fittings are clean and dry prior to assembly.
2. Position the fuel rail crossover pipe (1) to the right fuel rails fitting (2) and left fuel rail fitting (3).
3. Tighten the fuel rail crossover pipe fittings. Tighten: Tighten the fittings first pass to 16 N.m (12 lb ft). Tighten the fittings final pass to 32 N.m (24 lb ft).
4. Inspect for leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
5. Install the low side fuel pressure service port cap.
6. Install the fuel tank cap.
7. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-338138-S38398417812009081700000) .
8. Install the high pressure pump shield. Refer to «Fuel Pipe Shield Replacement (LLT)»(ref-338169-S21766103372009081700000) .
9. Install the fuel injection sight shield. Refer to «Fuel Injector Sight Shield Replacement (LLT)»(ref-338138-S06537109962009081700000) .

1. Remove the fuel injection sight shield. Refer to «Fuel Injector Sight Shield Replacement (LLT)»(ref-338138-S06537109962009081700000) .
2. Remove the high pressure pump shield. Refer to «Fuel Pipe Shield Replacement (LLT)»(ref-338169-S21766103372009081700000) .
3. Relieve fuel system pressure. Refer to «Fuel Pressure Relief (With High Pressure Pump - LLT)»(ref-338169-S29520756722009081700000) .
4. Remove the foam insulator from the pipes.
5. Loosen the high pressure pipe fitting to the high pressure fuel pump (1).
6. Loosen the high pressure pipe fitting to the left fuel rail (3).
7. Remove the high pressure fuel pipe (2) from the vehicle. Discard the pipe.

1. Ensure that the high pressure fuel pipe, fuel rail fitting and fuel pump fitting are clean and dry prior to assembly.
2. Position the high pressure fuel pipe (2) to the high pressure fuel pump fitting (1) and left fuel rail (3). hand tighten the fitting.
3. Tighten the high pressure fuel pipe fitting. Tighten: Tighten the fitting a first pass to 16 N.m (12 lb ft). Tighten the fitting a final pass to 32 N.m (24 lb ft).
4. Inspect for leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
5. Install the low side fuel pressure service port cap.
6. Install the fuel tank cap.
7. Install the high pressure pump shield. Refer to «Fuel Pipe Shield Replacement (LLT)»(ref-338169-S21766103372009081700000) .
8. Install the fuel injection sight shield. Refer to «Fuel Injector Sight Shield Replacement (LLT)»(ref-338138-S06537109962009081700000) .

1. Remove the cross vehicle brace. Refer to «Cross Vehicle Brace Replacement»(ref-338113-S17625406482009081700000) .
2. Remove the fuel injection sight shield. Refer to «Fuel Injector Sight Shield Replacement (LLT)»(ref-338138-S06537109962009081700000) .
3. Remove the intake manifold insulator.
4. Remove the wiper transmission. Refer to «Windshield Wiper Transmission Replacement»(ref-338129-S33321473932009081700000) .
5. Remove the fuel pipe shield to intake manifold bolts (1).
6. Remove the fuel pipe shield to cylinder bolt (1).
7. Carefully remove the fuel pipe shield from the vehicle. Take care not to damage the insulation behind the shield.

1. Position the fuel pipe shield behind the high pressure fuel pump. Take care not to damage the insulation behind the shield.
2. Install the fuel pipe shield to cylinder bolt (1). Hand tighten at this time.
3. Install the fuel pipe shield to intake manifold bolts (1). Tighten: Tighten the fuel pipe shield to manifold bolts to 23 N.m (17 lb ft). Tighten the fuel pipe shield to head bolt to 10 N.m (89 lb in).
4. Install the wiper transmission. Refer to «Windshield Wiper Transmission Replacement»(ref-338129-S33321473932009081700000) .
5. Install the fuel injection sight shield. Refer to «Fuel Injector Sight Shield Replacement (LLT)»(ref-338138-S06537109962009081700000) .
6. Install the cross vehicle brace. Refer to «Cross Vehicle Brace Replacement»(ref-338113-S17625406482009081700000) .

1. Relieve the low and high side fuel system pressure. Refer to «Fuel Pressure Relief (With High Pressure Pump - LLT)»(ref-338169-S29520756722009081700000) .
2. Remove the cross vehicle brace. Refer to «Cross Vehicle Brace Replacement»(ref-338113-S17625406482009081700000) .
3. Remove the high pressure fuel pump shield. Refer to «Fuel Pipe Shield Replacement (LLT)»(ref-338169-S21766103372009081700000) .
4. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-338138-S38398417812009081700000) .
5. Remove the wiper module. Refer to «Windshield Wiper Motor Replacement»(ref-338129-S21717842182009081700000) .
6. Disconnect the engine wiring harness electrical connector from the high pressure fuel pump.
7. Remove the radiator surge tank outlet pipe.
8. Remove the low pressure feed pipe. Refer to «Fuel Feed Pipe Replacement (LLT)»(ref-338169-S23318647162009081700000) .
9. Remove the high pressure pipe. Refer to «Fuel Feed Intermediate Pipe Replacement (LLT)»(ref-338169-S14101054272009081700000) . Discard this pipe.
10. Remove and discard the high pressure fuel pump bolts (4).
11. Remove the high pressure fuel pump (3).
12. Remove and discard the high pressure fuel pump gasket (2).
13. Remove and discard the high pressure fuel pump O-ring.
14. Remove the high pressure fuel pump roller lifter.

1. Use the EN-48896 to ensure that the camshaft lobe is in the base circle position. See «Special Tools»(ref-338169-S23212902312009081700000) . At base circle the tool will be flush with the head.
2. Lubricate the high pressure fuel pump cylinder head bore and roller lifter with camshaft prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent.
3. Install high pressure fuel pump roller lifter.
4. Install a NEW high pressure fuel pump O-ring.
5. Position the NEW high pressure fuel pump gasket (2) and bolts (4) to the fuel pump.
6. Install the high pressure fuel pump (3) to the cylinder head (1). Force will be required while hand tightening the bolts.
7. Tighten the high pressure fuel pump retaining bolts. Tighten: Tighten the fuel pump bolts to 15 N.m (11 lb ft).
8. Ensure the high pressure fuel pump and fuel rail fittings are clean prior to assembly.
9. Install a NEW high pressure fuel pipe. Refer to «Fuel Feed Intermediate Pipe Replacement (LLT)»(ref-338169-S14101054272009081700000) .
10. Install the fuel feed pipe to the high pressure fuel pump. Refer to «Fuel Feed Pipe Replacement (LLT)»(ref-338169-S23318647162009081700000) .
11. Connect the high pressure fuel pump wiring harness.
12. Install the radiator surge tank outlet pipe.
13. Install the fuel tank cap.
14. Inspect for leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
15. Install the pressure relief cap to the fuel feed pipe.
16. Install the wiper module. Refer to «Windshield Wiper Motor Replacement»(ref-338129-S21717842182009081700000) .
17. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-338138-S38398417812009081700000) .
18. Install the high pressure fuel pump shield. Refer to «Fuel Pipe Shield Replacement (LLT)»(ref-338169-S21766103372009081700000) .
19. Install the cross vehicle brace. Refer to «Cross Vehicle Brace Replacement»(ref-338113-S17625406482009081700000) .

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (With High Pressure Pump - LLT)»(ref-338169-S29520756722009081700000) .
2. Remove the upper intake manifold with the lower intake manifold.
3. Remove the fuel pipe retaining clip.
4. Disconnect the fuel feed pipe (2) from the fuel injector rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-338169-S19593842732009081700000) .
5. Use compressed air in order to remove debris from the area where the fuel injectors enter the intake manifold.
6. Remove the fuel rail bolts.
7. Remove the fuel rail with the fuel injectors.
8. Disengage the fuel injector electrical connector lock.
9. Disconnect the fuel injector electrical connector.
10. Remove the fuel injector retainer clip.
11. Remove the fuel injector.
12. Remove and discard the fuel injector seals.

1. Install NEW fuel injector seals.
2. Install the fuel injector.
3. Install the fuel injector retainer clip.
4. Install the fuel injector electrical connector.
5. Engage the fuel injector electrical connector lock.
6. Install the fuel rail with the fuel injectors.
7. Install the fuel rail bolts. Tighten: Tighten the fuel rail bolts to 10 N.m (89 lb in).
8. Connect the fuel feed pipe (2) to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-338169-S19593842732009081700000) .
9. Install the fuel pipe retaining clip.
10. Install the upper intake manifold.

1. Relieve the high side fuel system pressure. Refer to «Fuel Pressure Relief (With High Pressure Pump - LLT)»(ref-338169-S29520756722009081700000) .
2. Remove the fuel injection fuel rail assembly. Refer to «Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (LLT)»(ref-338169-S16708068992009081700000) or «Fuel Injection Fuel Rail Assembly Replacement - Bank 2 (LLT)»(ref-338169-S41688009542009081700000) .
3. Remove and discard the three fuel injector retaining rings (1).
4. Remove the direct fuel injectors and harness (1) as an assembly, and disconnect the electrical connector (2). If necessary, use the J 2619-01 with the J-37281-A in order to remove the direct fuel injectors evenly. See «Special Tools»(ref-338169-S23212902312009081700000) .
5. Remove and discard the following components from the fuel injectors (4). Upper O-ring Seal (1) Plastic Spacer (2) Retaining Ring (3) Isolator Cup (5) Teflon Seal (6)
6. Inspect the fuel rail injector bores and clean with J 39313 , and EN-47909 , if required. See «Special Tools»(ref-338169-S23212902312009081700000) .

1. Install the following NEW components to the fuel injectors. Use steps 2 through 8 to install these components. Upper O-ring Seal (1) Plastic Spacer (2) Retaining Ring (3) Isolator Cup (5) Teflon Seal (6)
2. From the EN-48266 , position the EN 48266-1 to the injector tip. See «Special Tools»(ref-338169-S23212902312009081700000) .
3. Install a NEW teflon seal onto the EN 48266-1.
4. Pull the NEW teflon seal by hand over the EN 48266-1 and into the groove in the injector.
5. Remove the EN 48266-1 from the injector tip.
6. From the EN-48266 , install the EN 48266-2 to the injector tip. See «Special Tools»(ref-338169-S23212902312009081700000) .
7. Using the EN 48266-2, resize the teflon seal. Install the EN 48266-2, until it bottoms out against the injector body, and rotate the EN 48266-2 while applying only moderate force 180 degrees in one direction and then 180 degrees back in the other direction.
8. Remove the EN 48266-2.
9. Install the direct fuel injectors and harness (1) as an assembly and connect the electrical connector (2).
10. Install the fuel injection fuel rail assembly. Refer to «Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (LLT)»(ref-338169-S16708068992009081700000) or «Fuel Injection Fuel Rail Assembly Replacement - Bank 2 (LLT)»(ref-338169-S41688009542009081700000) .

1. Turn the ignition OFF.
2. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement (LLT)»(ref-338138-S06537109962009081700000) .
3. Disconnect the purge line (3) from the purge valve solenoid.
4. Disconnect the purge valve solenoid electrical connector.
5. Disconnect the purge line from the manifold side of the purge valve solenoid.
6. Remove the purge valve solenoid from the bracket.

1. Install the purge valve solenoid to the bracket.
2. Disconnect the purge line from the manifold side of the purge valve solenoid.
3. Disconnect the purge valve solenoid electrical connector.
4. Connect the purge line (3) to the purge valve solenoid.
5. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement (LLT)»(ref-338138-S06537109962009081700000) .

1. Remove the evaporative emission (EVAP) canister. Refer to «Evaporative Emission Canister Replacement»(ref-338169-S05163995012009081700000) .
2. Clean away any debris that may be present around the EVAP canister vent valve.
3. Twist the EVAP canister vent valve counterclockwise.
4. Pull the EVAP canister vent valve from the EVAP canister.

1. Insert the EVAP canister vent valve into the EVAP canister.
2. Twist the EVAP canister vent valve clockwise into the locked position.
3. Install the EVAP canister. Refer to «Evaporative Emission Canister Replacement»(ref-338169-S05163995012009081700000) .

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-338169-S07606469012009081700000) .
2. Remove the chassis to canister evaporative emission (EVAP) hose from the following: The body retainer (1) The 3 retaining features (2) on the fuel tank The retainer clip (3)
3. Remove the EVAP hose from the fuel tank.

1. Position the EVAP hose to the fuel tank.
2. Install the chassis to canister EVAP hose to the following: The body retainer (1) The 3 retaining features (2) on the fuel tank The retainer clip (3)
3. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-338169-S07606469012009081700000) .

1. Remove the rear frame. Refer to «Rear Frame Replacement»(ref-338127-S05016546182009081700000) .
2. Disconnect the evaporative emission (EVAP) hoses from the EVAP canister.
3. Disconnect the electrical connector from the EVAP canister.
4. Remove the EVAP canister retaining nuts.
5. Complete the following in order to remove the EVAP canister: Lower the rear of the canister enough to clear the 2 weld studs. Slide the canister rearward from the body brace.

1. Complete the following in order to install the EVAP canister: Insert the fresh air tube and tab on the canister forward into the body brace. Rotate the rear of the canister up over the 2 weld studs on the floor pan.
2. Install the EVAP canister retaining nuts and tighten to 6 N.m (53 lb in).
3. Connect the EVAP hoses to the EVAP canister.
4. Connect the electrical connector to the EVAP canister.
5. Install the rear frame. Refer to «Rear Frame Replacement»(ref-338127-S05016546182009081700000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
2. Using a 90 degree pick, disengage the lower filter cover clips.
3. Insert a flat-bladed tool between the filter cover and canister, and push up to disengage the upper clips.
4. Remove and discard the evaporative emission (EVAP) canister filter cover.
5. Remove and discard the EVAP canister filter.
6. Clean the inside of the EVAP canister filter housing with a clean shop towel.

1. Insert a NEW EVAP canister filter into the EVAP canister.
2. Install a NEW EVAP canister filter cover seal to a EVAP NEW canister cover.
3. Snap the EVAP canister filter cover onto the EVAP canister.
4. Lower the vehicle.

1. Install the ignition coil(s).
2. Install the ignition coil bolt(s) and tighten to 10 N.m (89 lb in).
3. Install the ignition coil electrical connector(s).
4. If necessary, install the intake manifold.
5. Install the engine cover. Refer to «Fuel Injector Sight Shield Replacement (LLT)»(ref-338138-S06537109962009081700000) .

1. Turn the ignition OFF.
2. Remove the engine cover. Refer to «Fuel Injector Sight Shield Replacement (LLT)»(ref-338138-S06537109962009081700000) .
3. If you are replacing the ignition coil for cylinder 2, remove and reposition the intake manifold. Perform the following steps: Disconnect the air cleaner duct from the throttle body. Disconnect the positive crankcase ventilation (PCV) hose from the right bank camshaft cover. NOTE: Do NOT separate the upper intake manifold from the lower intake manifold. Remove the intake manifold bolts. Remove the intake manifold brace bolts (1 and 2) and the brace. Remove and reposition the upper intake manifold with the lower intake manifold in order to gain sufficient clearance for ignition coil removal.
4. Remove the ignition coil electrical connector(s).
5. Remove the ignition coil bolt(s).
6. Remove the ignition coil(s).

1. Install the ignition coil(s).
2. Install the ignition coil bolt(s) and tighten to 10 N.m (89 lb in).
3. Install the ignition coil electrical connector(s).
4. If necessary, install the upper intake manifold.

1. Turn the ignition OFF.
2. Remove the ignition coil.
3. Use compressed air in order to remove debris from the spark plug cavity.
4. Remove the spark plug.

1. Ensure that the spark plug gap is equivalent to the spark plug gap specification. Refer to «Ignition System Specifications»(ref-338169-S27576788982009081700000) .
2. Install the spark plug and tighten to 20 N.m (15 lb ft).
3. Install the ignition coil.

1. Turn the ignition OFF.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
3. Remove the exhaust manifold heat shield to obtain access.
4. Disconnect the crankshaft position (CKP) electrical connector (3).
5. Remove the crankshaft sensor bolt.
6. Remove the crankshaft sensor.

1. Install the crankshaft position sensor.
2. Install the crankshaft position sensor bolt and tighten to 10 N.m (89 lb in).
3. Connect the CKP electrical connector (3).
4. Install the exhaust manifold heat shield and tighten to 10 N.m (89 lb in).
5. Lower the vehicle.

1. Turn the ignition OFF.
2. Remove the power steering fluid reservoir bolts and reposition the power steering fluid reservoir in order to provide access.
3. Remove the camshaft position (CMP) sensor electrical connector.
4. Remove the CMP sensor bolt.
5. Remove the CMP sensor.

1. Install the CMP sensor.
2. Install the CMP sensor bolt and tighten to 10 N.m (89 lb in).
3. Install the CMP sensor electrical connector.
4. Install the power steering fluid reservoir.

1. Turn the ignition OFF.
2. Remove the power steering fluid reservoir bolts and reposition the power steering fluid reservoir in order to provide access.
3. Remove the camshaft position (CMP) sensor electrical connector.
4. Remove the CMP sensor bolt.
5. Remove the CMP sensor.

1. Install the CMP sensor.
2. Install the CMP sensor bolt and tighten to 10 N.m (89 lb in).
3. Install the CMP sensor electrical connector.
4. Install the power steering fluid reservoir.

1. Turn the ignition OFF.
2. Remove the front compartment sight shields as necessary. Refer to «Front Compartment Sight Shields Replacement»(ref-338113-S37193842242009081700000) .
3. Disconnect the camshaft position (CMP) sensor electrical connector.
4. Remove the CMP sensor bolt.
5. Remove the CMP sensor.

1. Install the CMP sensor.
2. Install the CMP sensor bolt and tighten to 10 N.m (89 lb in).
3. Connect the CMP sensor electrical connector.
4. Install the front compartment sight shields as necessary. Refer to «Front Compartment Sight Shields Replacement»(ref-338113-S37193842242009081700000) .

1. Turn the ignition OFF.
2. Remove the front compartment sight shields as necessary. Refer to «Front Compartment Sight Shields Replacement»(ref-338113-S37193842242009081700000) .
3. Disconnect the camshaft position (CMP) sensor electrical connector.
4. Remove the CMP sensor bolt.
5. Remove the CMP sensor.

1. Install the CMP sensor.
2. Install the CMP sensor bolt and tighten to 10 N.m (89 lb in).
3. Connect the CMP sensor electrical connector.
4. Install the front compartment sight shields as necessary. Refer to «Front Compartment Sight Shields Replacement»(ref-338113-S37193842242009081700000) .

1. Turn the ignition OFF.
2. Remove the front compartment sight shields as necessary. Refer to «Front Compartment Sight Shields Replacement»(ref-338113-S37193842242009081700000) .
3. Disconnect the camshaft position (CMP) actuator valve electrical connector.
4. Remove the CMP actuator valve bolt.
5. Remove the CMP actuator valve.
6. Inspect the CMP actuator valve seal for damage. Replace the seal if necessary.

1. Inspect the CMP actuator valve seal for damage. Replace the seal if necessary.
2. Install the CMP actuator valve.
3. Install the CMP actuator valve bolt and tighten to 10 N.m (89 lb in).
4. Connect the CMP actuator valve electrical connector.
5. Install the front compartment sight shields as necessary. Refer to «Front Compartment Sight Shields Replacement»(ref-338113-S37193842242009081700000) .

1. Turn the ignition OFF.
2. Remove the front compartment sight shields as necessary. Refer to «Front Compartment Sight Shields Replacement»(ref-338113-S37193842242009081700000) .
3. Disconnect the camshaft position (CMP) actuator valve electrical connector.
4. Remove the CMP actuator valve bolt.
5. Remove the CMP actuator valve.
6. Inspect the CMP actuator valve seal for damage. Replace the seal if necessary.

1. Inspect the CMP actuator valve seal for damage. Replace the seal if necessary.
2. Install the CMP actuator valve.
3. Install the CMP actuator valve bolt and tighten to 10 N.m (89 lb in).
4. Connect the CMP valve electrical connector.
5. Install the front compartment sight shields as necessary. Refer to «Front Compartment Sight Shields Replacement»(ref-338113-S37193842242009081700000) .

1. Turn the ignition OFF.
2. Remove the power steering fluid reservoir bolts and reposition the power steering fluid reservoir in order to provide access.
3. Remove the camshaft position (CMP) actuator valve electrical connector.
4. Remove the CMP actuator valve bolt.
5. Remove the CMP actuator valve.
6. Inspect the CMP actuator valve seal for damage and replace as necessary.

1. Inspect the CMP actuator valve seal for damage. Replace the seal if necessary.
2. Install the CMP actuator valve.
3. Install the CMP actuator valve bolt and tighten to 10 N.m (89 lb in).
4. Install the CMP actuator valve electrical connector.
5. Install the power steering fluid reservoir.

1. Turn the ignition OFF.
2. Remove the power steering fluid reservoir bolts and reposition the power steering fluid reservoir in order to provide access.
3. Remove the camshaft position (CMP) actuator valve electrical connector.
4. Remove the CMP actuator valve bolt.
5. Remove the CMP actuator valve.
6. Inspect the CMP actuator valve seal for damage and replace as necessary.

1. Inspect the CMP actuator valve seal for damage. Replace the seal if necessary.
2. Install the CMP actuator valve.
3. Install the CMP actuator valve bolt and tighten to 10 N.m (89 lb in).
4. Install the CMP actuator valve electrical connector.
5. Install the power steering fluid reservoir.

1. Turn the ignition OFF.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
3. Reposition the wiring harness heat shield to obtain access.
4. Remove the knock sensor (KS) electrical connector.
5. Remove the KS bolt.
6. Remove the KS.

1. Install the KS.
2. Install the KS bolt and tighten to 23 N.m (17 lb ft).
3. Install the KS electrical connector.
4. Install the wiring harness heat shield to the original position.
5. Lower the vehicle.

1. Turn the ignition OFF.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
3. Remove the wiring harness heat shield from the oil level indicator tube to gain access.
4. Remove the knock sensor (KS) electrical connector.
5. Remove the KS bolt.
6. Remove the KS.

1. Install the KS.
2. Install the KS bolt and tighten to 23 N.m (17 lb ft).
3. Install the KS electrical connector.
4. Install the wiring harness heat shield to the oil level indicator tube.
5. Lower the vehicle.

1. Remove the upper intake manifold with the lower intake manifold.
2. Remove the intake manifold runner control solenoid bolts.
3. Remove the intake manifold runner control solenoid.

1. Install the intake manifold runner control solenoid.
2. Install the intake manifold runner control solenoid bolts and tighten to 10 N.m (89 lb in).
3. Install the upper intake manifold.

1. Remove the air cleaner intake duct. Refer to «Air Cleaner Inlet Duct Replacement»(ref-338169-S06455195582009081700000) .
2. Loosen the air cleaner cover screws.
3. Open the air cleaner cover and remove the air cleaner element.

1. Install the air cleaner element and close the air cleaner cover.
2. Install the air cleaner cover screws and tighten to 8 N.m (71 lb in).
3. Install the air cleaner intake duct. Refer to «Air Cleaner Inlet Duct Replacement»(ref-338169-S06455195582009081700000) .

1. Turn the ignition OFF.
2. Remove the air cleaner intake duct. Refer to «Air Cleaner Inlet Duct Replacement»(ref-338169-S06455195582009081700000) .
3. Disconnect the mass air flow (MAF) electrical connector.
4. Remove the air cleaner bolts.
5. Remove the air cleaner.

1. Install the air cleaner.
2. Install the air cleaner bolts and tighten to 9 N.m (78 lb in).
3. Connect the MAF electrical connector.
4. Install the air cleaner intake duct. Refer to «Air Cleaner Inlet Duct Replacement»(ref-338169-S06455195582009081700000) .

1. Turn the ignition OFF.
2. Remove the front compartment sight shields as necessary. Refer to «Front Compartment Sight Shields Replacement»(ref-338113-S37193842242009081700000) .
3. Remove the positive crankcase ventilation (PCV) hose from the air cleaner duct resonator.
4. Loosen the air cleaner duct clamps.
5. Remove the air cleaner duct.

1. Install the air cleaner intake duct.
2. Install the PCV hose to the intake duct resonator.
3. Tighten the air cleaner duct clamps and tighten to 4 N.m (35 lb in).
4. Install the front compartment sight shields as necessary. Refer to «Front Compartment Sight Shields Replacement»(ref-338113-S37193842242009081700000) .