Home ReviewsRefund
Home/Cadillac/STS/Cadillac STS I facelift (2007-2011)/Repair manual/Testing & Diagnostics/Engine Controls and Fuel - 4.6L - Introduction: Removal & I…
Contents Wiring diagrams Section: Testing & Diagnostics All sections

Engine Controls and Fuel - 4.6L - Introduction: Removal & Installation Cadillac STS I facelift

Testing & Diagnostics ~7887 words

Removal Procedure

CAUTIONTurn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. The replacement control module must be programmed.

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 5 000 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 83 000 km (50,000 mi) from the last automatic transmission fluid change.

  1. Using a scan tool, retrieve the percentage of remaining engine oil and the remaining automatic transmission fluid life. Record the remaining engine oil and the remaining automatic transmission fluid life.
  2. Turn OFF the ignition.
  3. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection (Side Post)»(ref-338135-S42862392442009081700000) .
  4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
  5. Remove the front air deflector. Refer to «Front Air Deflector Replacement»(ref-338114-S23457007412009081700000) .
  6. Disconnect the engine control module (ECM) electrical connectors (1).
  7. Remove the ECM mounting nuts (2).
  8. Remove the ECM from the vehicle.

Installation Procedure

  1. Install the ECM to the vehicle.
  2. Install the ECM mounting nuts (2) and tighten to 8 N.m (71 lb in).
  3. Connect the ECM electrical connectors (1).
  4. Install the front air deflector. Refer to «Front Air Deflector Replacement»(ref-338114-S23457007412009081700000) .
  5. Lower the vehicle.
  6. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection (Side Post)»(ref-338135-S42862392442009081700000) .
  7. Program the ECM. Refer to «Control Module References»(ref-338152-S12253781062009081700000) for programming and setup information.
CAUTIONUse care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.
  1. Turn OFF the ignition
  2. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  3. Drain the coolant to below the level of the engine coolant temperature (ECT) sensor. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
  4. Disconnect the ECT sensor harness connector.
  5. Remove the ECT sensor.
CAUTIONUse care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.
CAUTIONReplacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage.
  1. Coat the sensor threads with sealer GM P/N 1050805, or equivalent.
  2. Install the ECT sensor and tighten to 20 N.m (15 lb ft).
  3. Connect the ECT sensor harness connector.
  4. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  5. Refill the coolant system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
  1. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector.
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338170-S38900360272009081700000) .
  3. Remove the MAF/IAT sensor screws.
  4. Carefully remove the MAF/IAT sensor from the air cleaner housing cover.
  5. Discard the MAF/IAT sensor gasket.
  1. Install a NEW MAF/IAT sensor gasket.
  2. Carefully install the MAF/IAT sensor into the air cleaner housing cover.
  3. Install the MAF/IAT sensor screws and tighten to 4 N.m (35 lb in).
  4. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338170-S38900360272009081700000) .
  5. Reconnect the MAF/IAT sensor electrical connector.
  1. Turn the ignition OFF.
  2. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  3. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
  4. Remove the bolt (1) and bracket (2) from the MAP sensor (3).
  5. Remove the MAP sensor (3).
  6. Inspect the MAP sensor seal for wear or damage. If a problem is found, replace as necessary.
  1. Install the MAP sensor (3).
  2. Install the bracket (2) and bolt (1) and tighten to 12 N.m (106 lb in).
  3. Connect the MAP sensor electrical connector.
  4. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
CAUTIONRefer to Oxygen Sensor Caution .

Note. Bank 1 on the LH2 engine in this vehicle is the right side of the engine while sitting in the driver seat. Sensor 1 is the sensor closest to the engine, or farthest forward toward the front of vehicle. A special anti-seize compound is used on the oxygen sensor threads. New service sensors should already have the compound applied to the threads. Coat the threads of a reused sensor with anti-seize compound P/N 5613695 or equivalent.

  1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  2. Disconnect the oxygen sensor electrical connector from the engine wiring harness connector at the rear of the right head.
  3. Note the wire routing and attachment points for reassembly.
  4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
  5. Remove oxygen sensor from the exhaust manifold.
  1. Install the heated oxygen sensor (HO2S) in the exhaust manifold and tighten to 42 N.m (31 lb ft).
  2. Lower the vehicle.
  3. Route and attach the wiring as noted in disassembly.
  4. Connect the oxygen sensor electrical connector to the engine wiring harness connector at the rear of the right head.
  5. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
CAUTIONRefer to Oxygen Sensor Caution .

Note. Bank 1 on the LH2 engine in this vehicle is the right side of the engine while sitting in the driver seat. Sensor 2 is the second sensor down stream from the engine towards the rear of the vehicle. A special anti-seize compound is used on the oxygen sensor threads. New service sensors should already have the compound applied to the threads. Coat the threads of a reused sensor with anti-seize compound P/N 5613695 or equivalent.

  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
  2. Disconnect the oxygen sensor electrical connector.
  3. Note the wire routing and attachment points for reassembly.
  4. Remove the oxygen sensor from the exhaust pipe.
  1. Install the oxygen sensor (HO2S) to the exhaust pipe and tighten to 42 N.m (31 lb ft).
  2. Route and attach the wiring as noted during disassembly.
  3. Connect the oxygen sensor electrical connector.
  4. Lower the vehicle.
CAUTIONRefer to Oxygen Sensor Caution .

Note. Bank 2 on the LH2 engine in this vehicle is the left side of the engine while sitting in the driver seat. Sensor 1 is the sensor closest to the engine, or farthest towards the front of vehicle. A special anti-seize compound is used on the oxygen sensor threads. New service sensors should already have the compound applied to the threads. Coat the threads of a reused sensor with anti-seize compound P/N 5613695 or equivalent.

  1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  2. Disconnect the oxygen sensor electrical connector from the engine wiring harness at the rear of the left head.
  3. Note the wire routing and attachment points for reassembly.
  4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
  5. Remove the oxygen sensor from the exhaust manifold.
  1. Install the heated oxygen sensor (HO2S) to the exhaust manifold and tighten to 42 N.m (31 lb ft).
  2. Lower the vehicle.
  3. Route and attach the wiring as noted during disassembly.
  4. Connect the oxygen sensor electrical connector to the engine wiring harness connector at the rear of the left head.
  5. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
CAUTIONRefer to Oxygen Sensor Caution .

Note. Bank 2 on the LH2 engine in this vehicle is the left side of the engine while sitting in the driver seat. Sensor 2 is the second sensor down stream from the engine towards the rear of the vehicle. A special anti-seize compound is used on the oxygen sensor threads. New service sensors should already have the compound applied to the threads. Coat the threads of a reused sensor with anti-seize compound P/N 5613695 or equivalent.

  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
  2. Disconnect the oxygen sensor electrical connector.
  3. Note the wire routing and attachment points for reassembly.
  4. Remove the oxygen sensor from the exhaust pipe.
  1. Install the oxygen sensor to the exhaust pipe. Tighten the front heated oxygen sensor (HO2S) to 42 N.m (31 lb ft).
  2. Route and attach the wiring as noted during disassembly.
  3. Connect the oxygen sensor electrical connector.
  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 mounting plate 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. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338170-S38900360272009081700000) .
  3. Disconnect the electrical connector from the throttle body assembly.
  4. Remove the throttle body assemble mounting bolts.
  5. Remove the throttle body and throttle body gasket from the water housing.
  6. Discard the throttle body gasket.
CAUTIONDo not use a cleaner which contains methyl ethyl ketone. This extremely strong solvent may damage components and is not necessary for this type of cleaning. Use a carburetor cleaner in order to remove deposits. Refer to the instructions provided with the cleaner.

Note. Do not reuse the old throttle body gasket.

  1. Install the NEW gasket to the throttle body assembly.
  2. Install the throttle body assembly to the water housing.
  3. Install the throttle body assembly mounting bolts and tighten to 10 N.m (89 lb in).
  4. Connect the electrical connector to the throttle body assembly.
  5. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338170-S38900360272009081700000) .
  6. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  7. Perform the Throttle Body Learn procedure. Refer to «Throttle Learn»(ref-338172-S31876752452009081700000) .
WARNINGRefer to Gasoline/Gasoline Vapors Warning .
WARNINGRemove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (With CH 48027)»(ref-338170-S38751865342009081700000) or «Fuel Pressure Relief (Without CH 48027)»(ref-338170-S30845267522009081700000) .
  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.
  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. Install the engine cover, if required.
  7. Tighten the fuel fill cap.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (With CH 48027)»(ref-338170-S38751865342009081700000) or «Fuel Pressure Relief (Without CH 48027)»(ref-338170-S30845267522009081700000) .
  2. Remove the retainer from the quick-connect fitting.
  3. Blow dirt out of the fitting using compressed air.
  4. Choose the correct tool for the size and access of the fitting: J 37088-A or J 44581 . Insert the tool into the female connector, then push inward to release the locking tabs.
  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. 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 fitting together to cause the retaining tabs to snap into place.
  3. Once installed, pull on both sides of the fitting to make sure the connection is secure.
  4. Install the retainer to the quick-connect fitting.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (With CH 48027)»(ref-338170-S38751865342009081700000) or «Fuel Pressure Relief (Without CH 48027)»(ref-338170-S30845267522009081700000) .
  2. Blow dirt out of the fitting using compressed air.
  3. Squeeze the plastic tabs of the male end connector.
  4. Pull the connection apart.
  5. Wipe off the male pipe end using a clean shop towel.
  6. Inspect both ends of the fitting for dirt and burrs.
  7. Clean or replace the components as required.
WARNINGIn order to reduce the risk of fire and personal injury, 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.
  1. Apply a few drops of clean engine oil to the male pipe end.
  2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs/fingers to snap into place.
  3. Pull on both sides of the quick connect fitting in order to make sure the connection is secure.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (With CH 48027)»(ref-338170-S38751865342009081700000) or «Fuel Pressure Relief (Without CH 48027)»(ref-338170-S30845267522009081700000) .
  2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
  3. Remove the rear suspension bracket. Refer to «Rear Suspension Bracket Replacement»(ref-338143-S12039122612009081700000) .
  4. Disconnect the quick-connect fittings (3 and 4) at the fuel filter inlet. Refer to «Metal Collar Quick Connect Fitting Service»(ref-338170-S27093434652009081700000) or «Plastic Collar Quick Connect Fitting Service»(ref-338170-S31950138632009081700000) .
  5. Disconnect the threaded fitting (1) at the fuel filter outlet.
  6. Drain any remaining fuel into an approved gasoline container.
  7. Remove the fuel filter (2).
  8. Remove the fuel pipe O-ring.
  9. Discard the fuel filter into an approved container.
  1. Remove the protective caps from the new fuel filter.
  2. If originally equipped, install new plastic connector retainers on the fuel filter inlets. Install the new retainers in the same position as on the old fuel filter.
  3. Lubricate the new fuel pipe O-ring with clean engine oil.
  4. Install the fuel pipe O-ring.
  5. Slide the fuel filter into place.
  6. Connect the quick-connect fittings (3 and 4) to the inlet side of the filter. Refer to «Metal Collar Quick Connect Fitting Service»(ref-338170-S27093434652009081700000) or «Plastic Collar Quick Connect Fitting Service»(ref-338170-S31950138632009081700000) .
  7. Connect the threaded fitting to the fuel filter outlet. Use a back-up wrench in order to prevent the fuel filter from turning. Tighten the fuel filter outlet fitting to 30 N.m (22 lb ft).
  8. Install the rear suspension bracket. Refer to «Rear Suspension Bracket Replacement»(ref-338143-S12039122612009081700000) .
  9. Lower the vehicle.
  10. Ensure that the fuel tank filler cap is installed correctly.
  11. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (Side Post)»(ref-338135-S42862392442009081700000) .
  12. Perform the following procedure in order to inspect for leaks: 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.
  13. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
WARNINGRefer to Gasoline/Gasoline Vapors Warning .
  1. Drain the fuel tank. Refer to «Fuel Tank Draining»(ref-338172-S24097542722009081700000) .
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (With CH 48027)»(ref-338170-S38751865342009081700000) or «Fuel Pressure Relief (Without CH 48027)»(ref-338170-S30845267522009081700000) .
  3. Remove the exhaust system. Refer to «Exhaust System Replacement»(ref-338131-S05393811512009081700000) .
  4. Remove the propeller shaft. Refer to «Rear Propeller Shaft Replacement (AWD)»(ref-338144-S22580991792009081700000) or «Rear Propeller Shaft Replacement (RWD)»(ref-338144-S39823555952009081700000) .
  5. Disconnect the filler hose (1) from the fuel tank.
  6. Disconnect the filler vent tube (2) from the evaporative emission (EVAP) hose. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-338170-S31950138632009081700000) .
  7. Refer to «Metal Collar Quick Connect Fitting Service»(ref-338170-S27093434652009081700000) or «Plastic Collar Quick Connect Fitting Service»(ref-338170-S31950138632009081700000) in order to disconnect the following from the chassis bundle: The fuel feed hoses (3 and 4) The fuel EVAP hose
  8. Disconnect the fuel tank electrical connector.
  9. Disconnect the EVAP hoses from the EVAP canister.
  10. Pull outward on the retainer tab in order to disengage the retainer from the chassis.
  11. Disconnect the electrical connector from the EVAP canister.
  12. Raise the lower control arms using a suitable screw jack (3) in order to remove the load from the lower shock bolts (2).
  13. Remove the lower shock bolts (2).
  14. Remove the screw jack (3).
  15. Position the screw jack under the rear frame near the adjuster tie bar, in order to support the front of the rear frame.
  16. Remove the 2 front bolts from the rear frame.
  17. Lower the screw jack until there is approximately 50 mm (2 in) (a) between the front mounting surface of the rear frame and the chassis. This will allow clearance to access the fuel tank strap bolts.
  18. Remove the fuel tank strap bolts.
  19. Position the fuel tank straps downward around the rear frame.
  20. Carefully bend the fuel tank straps ONLY enough to allow the fuel tank to be removed.
  21. With the aid of an assistant, carefully lower the fuel tank from the vehicle.
  22. Remove the following components if replacing just the fuel tank: The primary fuel tank module-Refer to «Primary Fuel Tank Module Replacement»(ref-338170-S02922558152009081700000) . The secondary fuel tank module-Refer to «Secondary Fuel Tank Module Replacement»(ref-338170-S40011182812009081700000) . The fuel tank pressure sensor-Refer to «Fuel Tank Pressure Sensor Replacement»(ref-338172-S00282628292009081700000) .
  1. Install the following components if fuel tank replacement was necessary: The primary fuel tank module-Refer to «Primary Fuel Tank Module Replacement»(ref-338170-S02922558152009081700000) . The secondary fuel tank module-Refer to «Secondary Fuel Tank Module Replacement»(ref-338170-S40011182812009081700000) . The fuel tank pressure sensor-Refer to «Fuel Tank Pressure Sensor Replacement»(ref-338172-S00282628292009081700000) .
  2. With the aid of an assistant, carefully raise the fuel tank to the vehicle, aligning the filler neck with the filler hose.
  3. Carefully bend the fuel tank straps back to their original form.
  4. Position the fuel tank straps around the rear frame and upward into position, aligning the holes in the straps with the threaded holes in the chassis.
  5. Install the fuel tank strap bolts and tighten to 50 N.m (37 lb ft).
  6. Connect the filler hose (1) to the fuel tank. Tighten the fuel filler tube hose clamp (3) to 3.5 N.m (31 lb in).
  7. Connect the filler vent tube (2) to the EVAP hose. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-338170-S31950138632009081700000) .
  8. Connect the EVAP hoses to the EVAP canister.
  9. Insert the retainer into the chassis and press inward on the tab to engage.
  10. Connect the electrical connector to the EVAP canister.
  11. Connect the fuel tank electrical connector.
  12. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-338170-S31950138632009081700000) or «Metal Collar Quick Connect Fitting Service»(ref-338170-S27093434652009081700000) in order to connect the following to the chassis bundle: The fuel feed hoses (3 and 4) The fuel EVAP hose
  13. Raise the rear frame using the screw jack.
  14. Install the 2 front bolts to the rear frame and tighten to 265 N.m (195 lb ft).
  15. Remove the screw jack.
  16. Position the screw jack (3) under the lower control arm in order to raise the lower control arms (2).
  17. Install the lower shock bolts (2) and tighten to 150 N.m (111 lb ft).
  18. Remove the screw jack (3).
  19. Install the propeller shaft. Refer to «Rear Propeller Shaft Replacement (AWD)»(ref-338144-S22580991792009081700000) or «Rear Propeller Shaft Replacement (RWD)»(ref-338144-S39823555952009081700000) .
  20. Install the exhaust system. Refer to «Exhaust System Replacement»(ref-338131-S05393811512009081700000) .
  21. Refill the fuel tank.
  22. 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-338172-S24097542722009081700000) .
  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-338170-S31950138632009081700000) .
  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. Tighten the fuel filler tube hose clamp (3) 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-338170-S31950138632009081700000) .
  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 hoses. Refer to «Fuel Hoses/Pipes Replacement - Filter to Tank»(ref-338170-S31427304892009081700000) .
  2. Disconnect the electrical connector from the primary fuel tank module.
  3. Rotate the cam lock ring counterclockwise using the J 45747 .
  4. Remove the cam lock ring from the fuel tank.
  5. Carefully lift the primary fuel tank module (1) from the fuel tank only enough to access the transfer tube (2).
  6. Complete the following in order to disconnect the transfer tube from the primary fuel tank module: Pull the locking mechanism away from the module. Remove the transfer tube from the module.
  7. Remove the primary fuel tank module from the fuel tank.
  8. Remove the primary fuel tank module seal from the module. Do not reuse the seal.
  1. Place the new primary fuel tank module seal (1) over the module (2).
  2. Complete the following in order to connect the transfer tube (2) to the primary fuel tank module (1). Grasp the transfer tube (2) from inside the fuel tank. Position the module (1) near the module opening. Connect the transfer tube (2) to the module (1).
  3. Carefully insert the primary fuel tank module (1) into the fuel tank.
  4. Press the primary fuel tank module (1) downward, aligning the module to the encapsulated ring.
  5. Position the cam lock ring to the fuel tank.
  6. Rotate the cam lock ring clockwise using the J 45747 until fully seated.
  7. Connect the electrical connector to the primary fuel tank module.
  8. Install the fuel tank hoses. Refer to «Fuel Hoses/Pipes Replacement - Filter to Tank»(ref-338170-S31427304892009081700000) .
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-338170-S26856500282009081700000) .
  2. Disconnect the electrical connector from the secondary fuel tank module.
  3. Rotate the cam lock ring counterclockwise using the J 45747 .
  4. Remove the cam lock ring from the fuel tank.
  5. Carefully lift the secondary fuel tank module (2) from the fuel tank only enough to access the transfer tube (1).
  6. Complete the following in order to disconnect the transfer tube from the secondary fuel tank module. Pull the locking mechanism away from the module. Remove the transfer tube from the module.
  7. Remove the secondary fuel tank module from the fuel tank.
  8. Remove the secondary fuel tank module seal from the module. Do not reuse the seal.
  1. Place the new secondary fuel tank module seal (1) over the module (2).
  2. Complete the following in order to connect the transfer tube (1) to the secondary fuel tank module (2). Grasp the transfer tube (1) from inside the fuel tank. Position the module (2) near the module opening. Connect the transfer tube (1) to the module (2).
  3. Carefully insert the secondary fuel tank module (2) into the fuel tank.
  4. Press the secondary fuel tank module (2) downward, aligning the module to the encapsulated ring.
  5. Position the cam lock ring to the fuel tank.
  6. Rotate the cam lock ring clockwise using the J 45747 until fully seated.
  7. Connect the electrical connector to the secondary fuel tank module.
  8. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-338170-S26856500282009081700000) .
WARNINGRefer to Gasoline/Gasoline Vapors Warning .
  1. Remove the primary fuel tank module. Refer to «Primary Fuel Tank Module Replacement»(ref-338170-S02922558152009081700000) .
  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-338170-S02922558152009081700000) .
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-338170-S26856500282009081700000) .
  2. Disconnect the following from the primary fuel tank module: The pressure hose The return hose
  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 following to the primary fuel tank module: The pressure hose The return hose
  4. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-338170-S26856500282009081700000) .

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 CH 48027)»(ref-338170-S38751865342009081700000) or «Fuel Pressure Relief (Without CH 48027)»(ref-338170-S30845267522009081700000) .
  2. Disconnect the feed hose/pipe (1) from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-338170-S27093434652009081700000) .
  3. Plug the open ports to prevent fuel loss and contamination.
  4. Disconnect the evaporative emission (EVAP) quick connect fitting (2). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-338170-S31950138632009081700000) .
  5. Open the retainers (1 and 2) located at the rear of the engine and on the front of dash.
  6. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
  7. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-338170-S31950138632009081700000) and «Metal Collar Quick Connect Fitting Service»(ref-338170-S27093434652009081700000) in order to disconnect the following quick connect fittings from the chassis bundle: The fuel filter (2) The fuel hose The fuel EVAP hose Plug the open outlet ports to prevent fuel loss and contamination.
  8. Pull the locking mechanism (1) outward in order to disengage the fuel/brake bundle chassis pipe retainers from the rail.
  9. Open the retainers (1) located at the forward portion of the rail in order to remove the chassis hose/pipes.
  10. 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).
  11. Pull downward in order to disconnect the fuel/brake bundle chassis pipe retainer from the underbody.
  12. Remove the bolt securing the fuel filter bracket to the body.
  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 bolts securing the transmission support to the underbody and tighten to 60 N.m (44 lb ft).
  6. Install the bolt securing the fuel filter bracket to the body and tighten to 9 N.m (80 lb in).
  7. Push upward in order to connect the fuel/brake bundle chassis pipe retainer to the underbody.
  8. 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.
  9. Install the chassis hose/pipes into the retainers (1) located at the forward portion of the rail.
  10. Close the retainers.
  11. Push the locking mechanism (1) inward in order to engage the fuel/brake bundle chassis pipe retainers to the rail.
  12. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-338170-S31950138632009081700000) and «Metal Collar Quick Connect Fitting Service»(ref-338170-S27093434652009081700000) in order to connect the following quick connect fittings to the chassis bundle: The fuel filter (2) The fuel hose The fuel EVAP hose
  13. Lower the vehicle.
  14. Insert the chassis hose/pipes into the retainers (1 and 2) located at the rear of the engine and the front of dash.
  15. Close the retainers.
  16. Connect the EVAP quick connect fitting (2). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-338170-S31950138632009081700000) .
  17. Connect the fuel feed pipe (1) to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-338170-S27093434652009081700000) .
  18. Check the fuel system for leaks.
  19. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .

Assemble the fuel system as follows

  1. Install the fuel injectors and fuel rail. Refer to «Fuel Injector and Fuel Rail Replacement»(ref-338170-S39764254292009081700000) .
  2. Install the fuel module assemblies. Refer to «Primary Fuel Tank Module Replacement»(ref-338170-S02922558152009081700000) and «Secondary Fuel Tank Module Replacement»(ref-338170-S40011182812009081700000) .
  3. Install the fuel filter. Refer to «Fuel Filter Replacement»(ref-338170-S16458682712009081700000) .
  4. Connect the fuel line to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-338170-S27093434652009081700000) .
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (With CH 48027)»(ref-338170-S38751865342009081700000) or «Fuel Pressure Relief (Without CH 48027)»(ref-338170-S30845267522009081700000) .
  2. Remove the cross vehicle brace. Refer to «Cross Vehicle Brace Replacement»(ref-338113-S17625406482009081700000) .
  3. Clean the fuel rail assembly with a spray type engine cleaner, GM X-30A or equivalent, if necessary. Follow the package instructions. Do not soak the fuel rail in liquid cleaning solvent.
  4. Disconnect the fuel feed hose/pipe (1) from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-338170-S27093434652009081700000) .
  5. Remove the positive crankcase ventilation (PCV) dirty air hose.
  6. Disconnect the evaporative emission (EVAP) quick connect fitting (2). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-338170-S31950138632009081700000) .
  7. Open the retainers (1 and 2) located at the right side rear of the engine and the front of dash. Position the lines aside.
  8. Disconnect the left side fuel injector wiring harness connectors (1) from the fuel injectors (2).
  9. Disconnect the right side fuel injector wiring harness connectors (1) from the fuel injectors (2).
  10. Remove the fuel injector sight shield bracket.
  11. Remove the fuel rail attaching studs.
  12. Remove the fuel rail assembly.
  13. Remove the injector lower O-ring seal from the spray tip end of each injector.
  14. Discard the O-ring seals.
  15. Remove the retainers from the fuel injectors.
  16. Remove the fuel injectors from the fuel rail.
  17. Remove the O-ring seals from the fuel injectors. Discard the O-ring seals.
  1. Lubricate the new fuel injector O-ring seals with clean engine oil.
  2. Install the new fuel injector O-ring seals on to the fuel injectors.
  3. Install the fuel injectors to the fuel rail using new retainer clips.
  4. Ensure that the injectors are aligned by orientating the electrical connectors perpendicular to the crankshaft centerline.
  5. Lubricate and install the new O-ring seals on the spray tip end of each injector.
  6. Align the fuel injectors and fuel rail to the intake manifold.
  7. Carefully press the fuel rail assembly downward until fully seated against the intake manifold.
  8. Install the fuel rail attaching studs and tighten to 10 N.m (89 lb in).
  9. Install the fuel injector sight shield bracket nuts and tighten to 10 N.m (89 lb in).
  10. Connect the right side fuel injector electrical connectors (1) to each fuel injector (2).
  11. Connect the left side fuel injector electrical connectors (1) to each fuel injector (2).
  12. Install the fuel feed and EVAP lines to the retaining clips (1 and 2) at the right side rear of the engine and at the front of dash.
  13. Install the EVAP quick connect fitting (2) to the purge valve. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-338170-S31950138632009081700000) .
  14. Install the positive crankcase ventilation (PCV) dirty air hose.
  15. Connect the fuel feed hose/pipe to the fuel rail (1). Refer to «Metal Collar Quick Connect Fitting Service»(ref-338170-S27093434652009081700000) .
  16. Install the cross vehicle brace. Refer to «Cross Vehicle Brace Replacement»(ref-338113-S17625406482009081700000) .
  17. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (Side Post)»(ref-338135-S42862392442009081700000) .
  18. 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.
  19. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  1. Loosen the fuel cap in order to relieve the system pressure.
  2. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  3. Disconnect the evaporative emission (EVAP) canister purge valve electrical connector (1).
  4. Disconnect the EVAP purge pipe (2) from the EVAP canister purge valve.
  5. Remove the EVAP canister purge valve retaining bolt.
  6. Remove the EVAP canister purge valve from the water housing.
  1. Lubricate the O-ring with clean engine oil.
  2. Install the EVAP canister purge valve to the water housing.
  3. Install the EVAP canister purge valve retaining bolt and tighten to 12 N.m (106 lb in).
  4. Connect the EVAP purge pipe (2) to the EVAP canister purge valve.
  5. Connect the EVAP canister purge valve electrical connector (1).
  6. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  1. Remove the evaporative emission (EVAP) canister. Refer to «Evaporative Emission Canister Replacement»(ref-338170-S28380566042009081700000) .
  2. Clean away any debris that may be present around the EVAP canister vent valve.
  3. Twist the EVAP canister vent valve counter-clockwise.
  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-338170-S28380566042009081700000) .
CAUTIONDo not attempt to straighten kinked nylon pipes. Replace any kinked nylon pipes in order to prevent damage to the vehicle. Do not attempt to repair sections of nylon pipes. Replace damaged nylon pipes. Replace the vapor hoses/pipes with original equipment or parts that meet GM specifications.
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-338170-S26856500282009081700000) .
  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 evaporative emission (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-338170-S26856500282009081700000) .
  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. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  2. Remove the ignition coil cover from the cam cover by lifting straight up.
  3. Disconnect the ignition coil wiring harness electrical connector from the coil that needs to be replaced.
  4. Remove the ignition coil retaining bolt.
  5. Carefully remove the ignition coil.
  1. Install the ignition coil.
  2. Install the ignition coil retaining bolt and tighten to 10 N.m (89 lb in).
  3. Reconnect the ignition coil electrical connector.
  4. Install the ignition coil cover to the cam cover.
  5. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  2. Remove the ignition coil cover from the cam cover by lifting straight up.
  3. Disconnect the ignition coil wiring harness electrical connector from the coil that needs to be replaced.
  4. Remove the ignition coil retaining bolt.
  5. Carefully remove the ignition coil assembly.
  1. Install the ignition coil.
  2. Install the ignition coil retaining bolt and tighten to 10 N.m (89 lb in).
  3. Reconnect the ignition coil electrical connector.
  4. Install the ignition coil cover to the cam cover.
  5. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  1. Remove the ignition coils. Refer to «Ignition Coil Replacement - Bank 1»(ref-338170-S24449734202009081700000) and/or «Ignition Coil Replacement - Bank 2»(ref-338170-S39399506772009081700000) .
  2. Clean the spark plug recess area with low pressure air.
  3. Remove the spark plugs from the cylinder heads.
  4. Inspect the spark plugs. Refer to «Spark Plug Inspection»(ref-338172-S11567356692009081700000) .
  1. Measure the spark plug gap on the spark plugs to be installed. Compare the measurement to the gap specifications. Refer to «Ignition System Specifications»(ref-338170-S16082956112009081700000) , correct as necessary.
  2. Install the spark plugs to the cylinder heads and tighten to 20 N.m (15 lb ft).
  3. Install the ignition coils. Refer to «Ignition Coil Replacement - Bank 1»(ref-338170-S24449734202009081700000) and/or «Ignition Coil Replacement - Bank 2»(ref-338170-S39399506772009081700000) .
  1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-338203-S18741468922009081700000) .
  2. Disconnect the crankshaft position sensor electrical connector.
  3. Remove the crankshaft sensor retaining bolt.
  4. Remove the crankshaft sensor.
  1. Lubricate the crankshaft sensor O-ring with clean engine oil.
  2. Install the crankshaft sensor and the retaining bolt and tighten to 10 N.m (89 lb in).
  3. Connect the crankshaft position sensor electrical connector.
  4. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-338203-S18741468922009081700000) .
  5. Perform the «Crankshaft Position System Variation Learn»(ref-338172-S14948253622009081700000) .
  1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  2. Disconnect the electrical connector from the left bank exhaust camshaft position sensor (2).
  3. Remove the camshaft sensor retaining bolt.
  4. Remove the left bank exhaust camshaft sensor (4).
  1. Lubricate the camshaft sensor O-ring with engine oil.
  2. Install the left bank exhaust camshaft position sensor (4) and retaining bolt and tighten to 10 N.m (89 lb in).
  3. Reconnect the camshaft sensor electrical connector (2).
  4. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  5. Operate the engine and inspect the camshaft sensor for engine oil leaks.
  1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  2. Disconnect the electrical connector from the left bank intake camshaft position sensor (1).
  3. Remove the camshaft sensor retaining bolt.
  4. Remove the left bank intake camshaft sensor (3).
  1. Lubricate the camshaft sensor O-ring with engine oil.
  2. Install the left bank intake camshaft position sensor (3) and retaining bolt. Tighten: Tighten the retaining bolt to 10 N.m (89 lb in).
  3. Reconnect the camshaft sensor electrical connector (1).
  4. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  5. Operate the engine and inspect the camshaft sensor for engine oil leaks.
  1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  2. Disconnect the electrical connector from the right bank exhaust camshaft position sensor (2).
  3. Remove the camshaft sensor retaining bolt.
  4. Remove the right bank exhaust camshaft sensor (1).
  1. Lubricate the camshaft sensor O-ring with engine oil.
  2. Install the right bank exhaust camshaft position sensor (1) and retaining bolt and tighten to 10 N.m (89 lb in).
  3. Reconnect the camshaft sensor electrical connector (2).
  4. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  5. Operate the engine and inspect the camshaft sensor for engine oil leaks.
  1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  2. Disconnect the electrical connector from the right bank intake camshaft position sensor (1).
  3. Remove the camshaft sensor retaining bolt.
  4. Remove the right bank intake camshaft sensor (2).
  1. Lubricate the camshaft sensor O-ring with engine oil.
  2. Install the right bank intake camshaft position sensor (2) and retaining bolt and tighten to 10 N.m (89 lb in).
  3. Reconnect the camshaft sensor electrical connector (1).
  4. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  5. Operate the engine and inspect the camshaft sensor for engine oil leaks.
  1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  2. Disconnect the actuator solenoid electrical connector.
  3. Remove the right intake camshaft position (CMP) actuator solenoid bolts.
  4. Remove the right intake CMP actuator solenoid.

Note. The CMP actuator solenoid must be precisely aligned to the CMP actuator oil control valve on the end of the camshaft. This is accomplished with an alignment pin. Failure to align the CMP actuator solenoid to the CMP actuator oil control valve can lead to poor engine performance.

To allow for CMP actuator solenoid to CMP actuator oil control valve alignment, DO NOT install the NEW CMP actuator solenoid alignment plugs at this time.

  1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  2. Disconnect the actuator solenoid electrical connector.
  3. Remove the right exhaust camshaft position (CMP) actuator solenoid bolts.
  4. Remove the right exhaust CMP actuator solenoid.

Note. The CMP actuator solenoid must be precisely aligned to the CMP actuator oil control valve on the end of the camshaft. This is accomplished with an alignment pin. Failure to align the CMP actuator solenoid to the CMP actuator oil control valve can lead to poor engine performance.

To allow for CMP actuator solenoid to CMP actuator oil control valve alignment, DO NOT install the NEW CMP actuator solenoid alignment plugs at this time.

  1. Remove the remote power steering reservoir. Refer to «Remote Power Steering Fluid Reservoir Replacement (LH2)»(ref-338163-S03593410672009081700000) .
  2. Disconnect the actuator solenoid electrical connector.
  3. Remove the left intake camshaft position (CMP) actuator solenoid bolts.
  4. Remove the left intake CMP actuator solenoid.

Note. The CMP actuator solenoid must be precisely aligned to the CMP actuator oil control valve on the end of the camshaft. This is accomplished with an alignment pin. Failure to align the CMP actuator solenoid to the CMP actuator oil control valve can lead to poor engine performance.

To allow for CMP actuator solenoid to CMP actuator oil control valve alignment, DO NOT install the NEW camshaft position actuator solenoid alignment plugs at this time.

  1. Remove the remote power steering reservoir. Refer to «Remote Power Steering Fluid Reservoir Replacement (LH2)»(ref-338163-S03593410672009081700000) .
  2. Disconnect the actuator solenoid electrical connector.
  3. Remove the left exhaust camshaft position (CMP) actuator solenoid bolts.
  4. Remove the left exhaust CMP actuator solenoid.

Note. The CMP actuator solenoid must be precisely aligned to the CMP actuator oil control valve on the end of the camshaft. This is accomplished with an alignment pin. Failure to align the CMP actuator solenoid to the CMP actuator oil control valve can lead to poor engine performance.

To allow for CMP actuator solenoid to CMP actuator oil control valve alignment, DO NOT install the NEW CMP actuator solenoid alignment plugs at this time.

  1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-338203-S18741468922009081700000) .
  2. Disconnect the knock sensor (KS) electrical connector (2).
  3. Remove the KS bolt.
  4. Remove the KS (1).
  1. Thoroughly clean the mating surfaces of the KS and the engine block. The entire contact surface of the KS must lie directly on the engine block.
  2. Install the KS (1) and tighten bolt to 20 N.m (15 lb ft).
  3. Ensure that the wiring harness is installed correctly.
  4. Connect the KS electrical connector (2).
  5. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-338203-S18741468922009081700000) .
  1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-338203-S18741468922009081700000) .
  2. Disconnect the knock sensor (KS) electrical connector (3).
  3. Remove the KS bolt.
  4. Remove the KS (4).
  1. Thoroughly clean the mating surfaces of the KS and the engine block. The entire contact surface of the KS must lie directly on the engine block.
  2. Install the KS (4) and tighten bolt to 20 N.m (15 lb ft).
  3. Ensure that the wiring harness is installed correctly.
  4. Connect the KS electrical connector (3).
  5. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-338203-S18741468922009081700000) .
  1. Remove the air cleaner outlet duct from the vehicle. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338170-S38900360272009081700000) .
  2. Remove the air cleaner housing screws.
  3. Open the air cleaner housing.
  4. Remove the air cleaner element.
  5. Remove any loose debris that may be found laying in the base of the air cleaner.
  1. Install the new air filter element.
  2. Close the air cleaner housing.
  3. Install the air cleaner housing screws and tighten to 3 N.m (27 lb in).
  4. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338170-S38900360272009081700000) .
  1. Remove the air cleaner outlet duct from the vehicle. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338170-S38900360272009081700000) .
  2. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector.
  3. Remove the MAF/IAT sensor if necessary. Refer to «Mass Airflow Sensor/Intake Air Temperature Sensor Replacement»(ref-338170-S12012975482009081700000) .
  4. Remove the coolant hose from the retaining feature on the top of the air cleaner assembly. Position the hose aside.
  5. Remove the screws securing the air cleaner assembly to the vehicle and remove the assembly.

Note. An improperly installed air cleaner or a distorted or missing intake air duct may cause a diagnostic trouble code (DTC) to set. Ensure that the air cleaner assembly and intake air duct is installed correctly and that there are no kinks or folds in the intake air duct. Debris in the air cleaner assembly or MAF sensor inlet screen, that may distort air flow can set a DTC.

  1. Install the air cleaner assembly into the vehicle.
  2. Install the air cleaner assembly screws and tighten to 10 N.m (89 lb in).
  3. Install the coolant hose into the retaining feature on the top of the air cleaner assembly.
  4. Install the MAF/IAT sensor if previously removed. Refer to «Mass Airflow Sensor/Intake Air Temperature Sensor Replacement»(ref-338170-S12012975482009081700000) .
  5. Connect the MAF/IAT sensor electrical connector.
  6. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338170-S38900360272009081700000) .
  1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
  2. Disconnect the positive crankcase ventilation (PCV) tube from the air cleaner duct.
  3. Loosen the air duct clamp at the throttle body.
  4. Loosen the air duct clamp at the mass air flow (MAF)/intake air temperature (IAT) sensor.
  5. Remove the air cleaner duct from the vehicle.
  1. Install the air cleaner duct to the vehicle.
  2. Tighten the air cleaner duct clamps at the throttle body and the MAF/IAT sensor to 3 N.m (27 lb in).
  3. Connect the PCV tube to the air cleaner duct.
  4. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .

More articles — Engine Controls and Fuel - 4.6L - Introduction