Temperature vs Resistance
| °C | °F | OHMS |
|---|---|---|
| Temperature vs Resistance Values (Approximate) | ||
| 150 | 302 | 47 |
| 140 | 284 | 60 |
| 130 | 266 | 77 |
| 120 | 248 | 100 |
| 110 | 230 | 132 |
| 100 | 212 | 177 |
| 90 | 194 | 241 |
| 80 | 176 | 332 |
| 70 | 158 | 467 |
| 60 | 140 | 667 |
| 50 | 122 | 973 |
| 45 | 113 | 1188 |
| 40 | 104 | 1459 |
| 35 | 95 | 1802 |
| 30 | 86 | 2238 |
| 25 | 77 | 2796 |
| 20 | 68 | 3520 |
| 15 | 59 | 4450 |
| 10 | 50 | 5670 |
| 5 | 41 | 7280 |
| 0 | 32 | 9420 |
| 5 | 23 | 12300 |
| 10 | 14 | 16180 |
| 15 | 5 | 21450 |
| 20 | 4 | 28680 |
| 30 | 22 | 52700 |
| 40 | 40 | 100700 |
Temperature vs Resistance
Altitude vs Barometric Pressure
| Altitude Measured in Meters (m) | Altitude Measured in Feet (ft) | Barometric Pressure Measured in Kilopascals (kPa) |
|---|---|---|
| Determine your altitude by contacting a local weather station or by using another reference source. | ||
| 4 267 | 14,000 | 56-64 |
| 3 962 | 13,000 | 58-66 |
| 3 658 | 12,000 | 61-69 |
| 3 353 | 11,000 | 64-72 |
| 3 048 | 10,000 | 66-74 |
| 2 743 | 9,000 | 69-77 |
| 2 438 | 8,000 | 71-79 |
| 2 134 | 7,000 | 74-82 |
| 1 829 | 6,000 | 77-85 |
| 1 524 | 5,000 | 80-88 |
| 1 219 | 4,000 | 83-91 |
| 914 | 3,000 | 87-95 |
| 610 | 2,000 | 90-98 |
| 305 | 1,000 | 94-102 |
| 0 | 0 Sea Level | 96-104 |
| 305 | 1,000 | 101-105 |
Altitude vs Barometric Pressure
Ignition System Specifications
| Application | Specification | |
|---|---|---|
| Metric | English | |
| Firing Order | 1-8-7-2-6-5-4-3 | |
| Spark Plug Wire Resistance | 1000 ohms per ft | |
| Spark Plug Torque | 15 N.m | 11 lb ft |
| Spark Plug Gap | 1.52 mm | 0.060 in |
| Spark Plug Type | 25171803 [AC plug type] 12567759 [NGK plug type] | |
Ignition System Specifications
Fastener Tightening Specifications
| Application | Specifications | |
|---|---|---|
| Metric | English | |
| 3-Phase Cable Bracket Nut | 15 N.m | 11 lb ft |
| 3-Phase Cable to Starter/Generator Control Module (SGCM) Nut | 9 N.m | 80 lb in |
| Accelerator Pedal Nut | 20 N.m | 15 lb ft |
| Air Cleaner Outlet Duct Clamp | 4 N.m | 35 lb in |
| Auxiliary Heater Water Pump Bracket Bolt | 15 N.m | 11 lb ft |
| Brake Pipe Fittings to Electronic Brake Control Module (EBCM) | 25 N.m | 18 lb ft |
| Camshaft Position (CMP) Sensor Bolt | 29 N.m | 21 lb ft |
| Canister Vent Solenoid (CVS) Bracket Bolt | 12 N.m | 106 lb in |
| Crankshaft Position (CKP) Sensor Bolt | 25 N.m | 18 lb ft |
| Electro-Hydraulic Control Unit (EHCU) Bolts | 25 N.m | 18 lb ft |
| Engine Coolant Temperature (ECT) Sensor | 20 N.m | 15 lb ft |
| Engine Wiring Harness Bracket Nut | 5 N.m | 44 lb in |
| EVAP Canister Bolt/Nut | 25 N.m | 18 lb ft |
| EVAP Canister Bracket Nut | 25 N.m | 18 lb ft |
| EVAP Canister Purge Solenoid Bolt | 10.5 N.m | 93 lb in |
| EVAP Vent Valve Bracket Bolt | 12 N.m | 106 lb in |
| Fuel Composition Sensor Nut | 17 N.m | 13 lb ft |
| Fuel Composition Sensor to Bracket Bolt | 10 N.m | 89 lb in |
| Fuel Feed and EVAP Pipe Assembly Nut | 12 N.m | 106 lb in |
| Fuel Line Fitting | 25 N.m | 18 lb ft |
| Fuel Pipe Bracket Nut | 10 N.m | 89 lb in |
| Fuel Rail Bolts | 10 N.m | 89 lb in |
| Fuel Tank Fill Pipe Clamp | 2.5 N.m | 22 lb in |
| Fuel Tank Filler Housing to Body Screw | 2.3 N.m | 20 lb in |
| Fuel Tank Filler Pipe Housing to Fuel Tank Fill Pipe Screw | 2.3 N.m | 20 lb in |
| Fuel Tank Ground Strap Bolt | 9 N.m | 80 lb in |
| Fuel Tank Shield Bolt | 18 N.m | 13 lb ft |
| Fuel Tank Strap Bolt | 40 N.m | 30 lb ft |
| Heated Oxygen Sensor (HO2S) | 42 N.m | 31 lb ft |
| Ignition Coil Bolt | 8 N.m | 71 lb in |
| Knock Sensor | 20 N.m | 15 lb ft |
| Mass Air Flow/Intake Air Temperature (MAF/IAT) Sensor Clamp | 7 N.m | 62 lb in |
| Powertrain Control Module (PCM) Electrical Connector Bolt | 8 N.m | 71 lb in |
| Rear Fuel Line Bundle Nut | 12 N.m | 106 lb in |
| Spark Plug | ||
| New Head | 20 N.m | 15 lb ft |
| Used Head | 15 N.m | 11 lb ft |
| Starter/Generator Control Module (SGCM) Cover Bolt | 9 N.m | 80 lb in |
| Throttle Actuator Control (TAC) Module Nut | 9 N.m | 80 lb in |
| Throttle Body Nut | 10 N.m | 89 lb in |
Fastener Tightening Specifications
Action Taken When the DTC Sets - Type A
The control module illuminates the malfunction indicator lamp (MIL) when the diagnostic runs and fails.
Action Taken When the DTC Sets - Type B
The control module illuminates the MIL on the second consecutive ignition cycle that the diagnostic runs and fails.
Conditions for Clearing the MIL/DTC - Type A or Type B
- The control module turns OFF the MIL after 3 consecutive ignition cycles that the diagnostic runs and does not fail.
- A current DTC Last Test Failed clears when the diagnostic runs and passes.
- Use a scan tool in order to clear the MIL and the DTC.
Action Taken When the DTC Sets - Type C
- The control module stores the DTC information into memory when the diagnostic runs and fails.
- The MIL will not illuminate.
- The driver information center, if equipped, may display a message.
Conditions for Clearing the DTC - Type C
- A last test failed, or current DTC, clears when the diagnostic runs and passes.
- Use a scan tool in order to clear the DTC.
Conditions for Clearing the DTC - Type X
This DTC is available in the PCM software, but has been disabled, or turned OFF. In this case, the diagnostic does not run, no DTCs are stored, and the MIL does not illuminate. Type X DTCs are used primarily for export vehicles that do not require MIL illumination or DTC storing.
Diagnostic Trouble Code (DTC) Type(s)
| DTC | United States Canada RPO NC1, NF2, NF4, and NT9 | United States Canada RPO L59, E85 | Unleaded Export Light Duty (less than 8600 GVWR) RPO NF9 | All Heavy Duty (more than 8600 GVW) RPO NC8, NF4, NT9, NF9 |
|---|---|---|---|---|
| P0053 | B | B | B | B |
| P0054 | B | B | B | B |
| P0059 | B | B | B | B |
| P0060 | B | B | B | B |
| P0068 | A | A | A | A |
| P0101 | B | B | B | B |
| P0102 | B | B | B | B |
| P0103 | B | B | B | B |
| P0106 | B | B | B | B |
| P0107 | B | B | B | B |
| P0108 | B | B | B | B |
| P0112 | B | B | B | B |
| P0113 | B | B | B | B |
| P0116 | B | B | B | X |
| P0117 | B | B | B | B |
| P0118 | B | B | B | B |
| P0120 | A | A | A | A |
| P0128 | B | B | B | X |
| P0131 | B | B | B | B |
| P0132 | B | B | B | B |
| P0133 | B | B | B (No MIL) | X |
| P0134 | B | B | B | B |
| P0135 | B | B | B (No MIL) | X |
| P0137 | B | B | B | B |
| P0138 | B | B | B | B |
| P0140 | B | B | B | B |
| P0141 | B | B | B (No MIL) | X |
| P0151 | B | B | B | B |
| P0152 | B | B | B | B |
| P0153 | B | B | B (No MIL) | X |
| P0154 | B | B | B | B |
| P0155 | B | B | B (No MIL) | X |
| P0157 | B | B | B | B |
| P0158 | B | B | B | B |
| P0160 | B | B | B | B |
| P0161 | B | B | B (No MIL) | X |
| P0169 | X | C | X | X |
| P0171 | B | B | B | B (No MIL) |
| P0172 | B | B | B | B (No MIL) |
| P0174 | B | B | B | B (No MIL) |
| P0175 | B | B | B | B |
| P0178 | X | B | X | X |
| P0179 | X | B | X | X |
| P0200 | B | B | B | B |
| P0218 | C | C | C | C |
| P0220 | A | A | A | A |
| P0230 | B | B | B | B (No MIL) |
| P0300 | B | B | B (No MIL) | B (No MIL) |
| P0315 | A | A | A | A |
| P0325 | B | B | B | B |
| P0327 | B | B | B | B |
| P0332 | B | B | B | B |
| P0335 | B | B | B | B |
| P0336 | B | B | B | B |
| P0341 | B | B | B | B |
| P0342 | B | B | B | B |
| P0343 | B | B | B | B |
| P0351 | B | B | B | B |
| P0352 | B | B | B | B |
| P0353 | B | B | B | B |
| P0354 | B | B | B | B |
| P0355 | B | B | B | B |
| P0356 | B | B | B | B |
| P0357 | B | B | B | B |
| P0358 | B | B | B | B |
| P0420 | A | A | A (No MIL) | X |
| P0430 | A | A | A (No MIL) | X |
| P0442 | A | A | X | X |
| P0443 | B | B | B | B |
| P0446 | B | B | B (No MIL) | X |
| P0449 | B | B | B (No MIL) | X |
| P0451 | A | A | A (No MIL) | X |
| P0452 | B | B | B (No MIL) | X |
| P0453 | B | B | B (No MIL) | X |
| P0454 | A | A | A (No MIL) | X |
| P0455 | B | B | B (No MIL) | X |
| P0461 | B | B | B (No MIL) | X |
| P0462 | B | B | B (No MIL) | B (No MIL) |
| P0463 | B | B | B (No MIL) | B (No MIL) |
| P0464 | A | A | A (No MIL) | X |
| P0496 | B | B | B (No MIL) | X |
| P0502 | B | B | B | B |
| P0503 | B | B | B | B |
| P0506 | B | B | B | B |
| P0507 | B | B | B | B |
| P0522 | C | C | C | C |
| P0523 | C | C | C | C |
| P0530 | C | C | C | C |
| P0562 | C | C | C | C |
| P0563 | C | C | C | C |
| P0567 | C | C | C | C |
| P0568 | C | C | C | C |
| P0601 | A | A | A | A |
| P0602 | A | A | A | A |
| P0604 | A | A | A | A |
| P0606 | A | A | A | A |
| P0608 | C | C | C | C |
| P0609 | C | C | C | C |
| P0622 | C | C | C | C |
| P0641 | B | B | B | B |
| P0650 | B (No MIL) | B (No MIL) | B (No MIL) | B (No MIL) |
| P0651 | B | B | B | B |
| P0654 | C | C | C | C |
| P0706 (Auto Trans Only) | C | C | C | C |
| P0711 | C | C | C | C |
| P0712 | C | C | C | C |
| P0713 | C | C | C | C |
| P0716 | B | B | X | B (No MIL) |
| P0717 | B | B | X | B (No MIL) |
| P0719 | C | C | C | C |
| P0724 | C | C | C | C |
| P0730 | C | C | X | C |
| P0740 | B | B | B | X |
| P0741 | B | B | B | B |
| P0742 | B | B | B | B |
| P0748 | C | C | C | C |
| P0751 | B | B | B | B (No MIL) |
| P0752 | B | B | B | B |
| P0753 | B | B | B | B |
| P0756 | A | A | A | A (No MIL) |
| P0757 | A | A | A | A (No MIL) |
| P0758 | A | A | A | A (No MIL) |
| P0785 | B | B | B | X |
| P0856 | C | C | C | X |
| P0894 | B | B | B | B |
| P1106 | C | C | C | C |
| P1107 | C | C | C | C |
| P1111 | C | C | C | C |
| P1112 | C | C | C | C |
| P1114 | C | C | C | C |
| P1115 | C | C | C | C |
| P1125 | A | A | A | A |
| P1133 | B | B | B (No MIL) | X |
| P1134 | B | B | B (No MIL) | X |
| P1153 | B | B | B (No MIL) | X |
| P1154 | B | B | B (No MIL) | X |
| P1258 | A | A | A | A |
| P1380 | C | C | X | X |
| P1381 | C | C | X | X |
| P1516 | A | A | A | A |
| P1574 | C | C | C | C |
| P1626 | C | C | C | C |
| P1631 | C | C | C | C |
| P1637 | C | C | C | C |
| P1689 | C | C | C | C |
| P1810 | B | B | B | B |
| P2066 | B | B | X | X |
| P2067 | B | B | X | B (No MIL) |
| P2068 | B | B | X | C |
| P2101 | A | A | A | A |
| P2108 | A | A | A | A |
| P2120 | A | A | A | A |
| P2121 | A | A | A | A |
| P2125 | A | A | A | A |
| P2135 | A | A | A | A |
| P2610 | B | B | B | B |
| P2636 | C | C | X | C |
| P2761 | B | B | B | B |
| P2771 | B | B | B | B (No MIL) |
| P2A01 | B | B | B (No MIL) | X |
| P2A04 | B | B | B (No MIL) | X |
| U0107 | A | A | A | A |
Diagnostic Trouble Code (DTC) Type(s)
Scheme 59
| Callout | Component Name |
|---|---|
| 1 | Manifold Absolute Pressure (MAP) Sensor |
| 2 | EVAP Canister Purge Hose |
| 3 | EVAP Service Port |
| 4 | Positive Crankcase Ventilation (PCV) Valve |
| 5 | Throttle Body |
| 6 | EVAP Canister Purge Valve |
| 7 | AIR Module, if equipped |
Scheme 60
| Callout | Component Name |
|---|---|
| 1 | EVAP Canister Purge Solenoid Valve |
| 2 | EVAP Canister |
| 3 | Fuel Fill Neck/Fill Cap |
| 4 | Rollover Valve/Fuel Tank Pressure (FTP) Sensor |
| 5 | Fuel Tank |
| 6 | EVAP Canister Vent Solenoid Valve |
| 7 | Vent Hose/Pipe |
| 8 | EVAP Vapor Pipe |
| 9 | EVAP Purge Pipe |
| 10 | EVAP Service Port |
Scheme 61
| Callout | Component Name |
|---|---|
| 1 | Fuel Pressure Service Connection |
| 2 | Fuel Injector Rail |
| 3 | Fuel Rail Feed Pipe |
| 4 | Fuel Feed Hose |
| 5 | Fuel Injector |
Engine Controls Schematic Icons
Engine Controls Schematic Icons Icon Icon Definition NOTE: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit
Scheme 62
Scheme 63
Scheme 64
Scheme 65
Scheme 66
Scheme 67
Scheme 68
Scheme 69
Scheme 70
Scheme 71
Scheme 72
Scheme 73
Scheme 74
Scheme 75
Scheme 76
Scheme 77
Scheme 78
| Callout | Component Name |
|---|---|
| 1 | Fuse Block - Underhood |
| 2 | Battery - Left |
| 3 | Powertrain Control Module (PCM) |
| 4 | Battery - Right (8Y9/TP2) |
Scheme 79
| Callout | Component Name |
|---|---|
| 1 | Ignition Coil 1 |
| 2 | Fuel Injector 1 |
| 3 | Fuel Injector 3 |
| 4 | Fuel Injector 5 |
| 5 | Fuel Injector 7 |
| 6 | Ignition Coil 7 |
| 7 | Ignition Coil 5 |
| 8 | Ignition Coil 3 |
| 9 | Engine Coolant Temperature (ECT) Sensor |
Scheme 80
| Callout | Component Name |
|---|---|
| 1 | Ignition Coil 8 |
| 2 | Fuel Injector 2 Connector |
| 3 | Fuel Injector 4 |
| 4 | Ignition Coil 2 |
| 5 | Ignition Coil 4 |
| 6 | Fuel Injector 6 |
| 7 | Ignition Coil 6 |
| 8 | Fuel Injector 8 |
Scheme 81
| Callout | Component Name |
|---|---|
| 1 | Manifold Absolute Pressure (MAP) Sensor |
| 2 | Throttle Body |
| 3 | Evaporative Emission (EVAP) Canister Purge Solenoid |
Scheme 82
| Callout | Component Name |
|---|---|
| 1 | Knock Sensor (KS) 1 |
| 2 | Knock Sensor (KS) 2 |
Scheme 83
| Callout | Component Name |
|---|---|
| 1 | Bank 1 Sensor 2 HO2S |
| 2 | Bank 1 Sensor 1 HO2S |
| 3 | Bank 1 Sensor 1 HO2S Threaded Boss |
| 4 | Left Bank Catalytic Convertor |
| 5 | Bank 1 Sensor 2 HO2S Threaded Boss |
| 6 | Bank 2 Sensor 1 HO2S Threaded Boss |
| 7 | Right Side Frame Rail |
| 8 | Right Bank Catalytic Convertor |
| 9 | Bank 2 Sensor 2 HO2S Threaded Boss |
| 10 | Bank 2 Sensor 2 HO2S |
| 11 | Bank 2 Sensor 1 HO2S |
Scheme 84
| Callout | Component Name |
|---|---|
| 1 | Bank 2 Sensor 1 HO2S |
| 2 | Bank 1 Sensor 2 HO2S Threaded Boss |
| 3 | Right Side Frame Rail |
| 4 | Right Bank Catalytic Convertor |
| 5 | Bank 2 Sensor 2 HO2S |
| 6 | Bank 2 Sensor 2 HO2S Threaded Boss |
| 7 | Left Bank Catalytic Convertor |
| 8 | Bank 1 Sensor 2 HO2S |
| 9 | Bank 1 Sensor 1 HO2S Threaded Boss |
| 10 | Bank 1 Sensor 1 HO2S |
| 11 | Bank 2 Sensor 1 HO2S Threaded Boss |
Scheme 85
| Callout | Component Name |
|---|---|
| 1 | Fuel Pump and Sender Assembly Connector |
| 2 | Fuel Pump and Sender Assembly - Primary |
Scheme 86
| Callout | Component Name |
|---|---|
| 1 | Fuel Pump and Sender Assembly - Secondary |
| 2 | Fuel Pump and Sender Assembly Connector |
Scheme 87
| Callout | Component Name |
|---|---|
| 1 | Fuel Pump Relay - Secondary |
Scheme 88
| Callout | Component Name |
|---|---|
| 1 | Fuel Pump and Sender Assembly |
| 2 | Fuel Tank Pressure (FTP) Sensor |
| 3 | Fuel Level Sensor |
Scheme 89
| Callout | Component Name |
|---|---|
| 1 | Fuel Composition Sensor |
Scheme 90
| Callout | Component Name |
|---|---|
| 1 | Left Frame Rail |
| 2 | Evaporative Emissions (EVAP) Canister Vent Solenoid |
| 3 | Fuel Tank |
| 4 | Evaporative Emissions (EVAP) Canister |
Scheme 91
| Callout | Component Name |
|---|---|
| 1 | Clamp |
| 2 | Air Duct |
| 3 | Clamp |
| 4 | Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor |
| 5 | Air Cleaner Assembly |
| 6 | Air Restriction Indicator |
Scheme 92
| Callout | Component Name |
|---|---|
| 1 | Throttle Actuator Control (TAC) Module |
| 2 | Throttle Actuator Control (TAC) Connector |
| 3 | Fuse Block - Underhood |
Scheme 93
| Callout | Component Name |
|---|---|
| 1 | Accelerator Pedal Position (APP) Sensor Connector |
| 2 | Accelerator Pedal Position (APP) Sensor |
Powertrain Control Module (PCM) Connector End Views
Powertrain Control Module (PCM) C1 Connector Part Information 12191489 80-Way F Micro-Pack 100 Series (BU) Pin Wire Color Circuit No. Function 1 BK/WH 451 Ground 2 L-GN 1867 12-Volt Reference 3 PK/BK 1746 Fuel Injector 3 Control 4 L-GN/BK 1745 Fuel Injector 2 Control 5-6 - - Not Used 7 GY 2705 5-Volt Reference 8-10 - - Not Used 11 L-BU 1876 Knock Sensor 2 Signal 12 D-BU/ WH 1869 CKP Sensor Signal 13 OG/BK 463 Requested Torque Signal 14 OG/BK 1061 UART Serial Data 15 D-BU/ WH 774 UART Serial Data 16 - - Not Used 17 D-BU 1225 Transmission Fluid Pressure Switch Signal B (A/T) 18 RD 1226 Transmission Fluid Pressure Switch Signal C (A/T) 19 PK 439 Ignition 1 Voltage 20 OG 440 Battery Positive Voltage 21 YE/BK 1868 Low Reference 22 - - Not Used 23 BK 470 Low Reference 24 BK/WH 451 Ground 25 TN 1671 HO2S Low Signal - Bank 2 Sensor 2 26 TN 1667 HO2S Low Signal - Bank 2 Sensor 1 27 BK/WH 451 Ground 28 TN/WH 1669 HO2S Low Signal - Bank 1 Sensor 2 29 TN 1664 HO2S Low Signal - Bank 1 Sensor 1 30 - 31 - - Not Used 32 BK/WH 771 Transmission Range Switch Signal A (A/T) 33 PU 420 TCC Brake Switch/Cruise Control Release Switch Signal 34 WH 776 Transmission Range Switch Signal P (A/T) 35 GY 48 CPP Switch Signal 36 BK 1744 Fuel Injector 1 Control 37 YE/BK 846 Fuel Injector 6 Control 38 PK/WH 1101 Damping Lift/Dive Signal (MN8 or MT1) 39 YE/BK 625 Starter Enable Relay Control 40 BK/WH 451 Ground 42 D-GN 335 Low Speed Cooling Fan Relay Control (10 Series) 43 RD/BK 877 Fuel Injector 7 Control 44 L-BU/BK 844 Fuel Injector 4 Control 45 GY 2700 5-Volt Reference (A/C) 46 GY 474 5-Volt Reference 47 - - Not Used 48 GY 597 5-Volt Reference 49-50 - - Not Used 51 D-BU 496 Knock Sensor 1 Signal 52 - - Not Used 53 GY 720 Low Reference (A/T) 54 OG/BK 469 Low Reference 55 - - Not Used 56 WH 1579 Fuel Temperature/Composition Signal (L59) 57 OG 440 Battery Positive Voltage 58 D-GN 1049 Class 2 Serial Data 59-60 - - Not Used 61 PK/BK 632 Low Reference 62 - - Not Used 63 BK 2755 Low Reference 64 BK/WH 451 Ground 65 PU 1670 HO2S High Signal - Bank 2 Sensor 2 66 PU 1666 HO2S High Signal - Bank 2 Sensor 1 67 BK/WH 451 Ground 68 PU/WH 1668 HO2S High Signal - Bank 1 Sensor 2 69 PU/WH 1665 HO2S High Signal - Bank 1 Sensor 1 70 BN 1174 Oil Level Switch Signal 71 - - Not Used 72 YE 772 Transmission Range Switch Signal B (A/T) 73 BN/WH 633 CMP Sensor Signal 74 YE 410 ECT Sensor Signal 75 PK 1020 Ignition 0 Voltage 76 BK/WH 845 Fuel Injector 5 Control 77 D-BU/ WH 878 Fuel Injector 8 Control 78 - - Not Used 79 WH 687 3-2 Shift Solenoid Valve Control (M30/M32/M33) 80 BK 407 Low Reference
Powertrain Control Module (PCM) C2 Connector Part Information 12191488 80-Way F Micro-Pack 100 Series (GN) Pin Wire Color Circuit No. Function 1 BK/WH 451 Ground 2 BN 418 TCC PWM Solenoid Valve Control (A/T) 3 TN 1465 Fuel Pump Relay Control - Secondary (Except L59/HP2) 4 - - Not Used 5 TN/BK 464 Delivered Torque Signal (NW7) 6 RD/BK 1228 PC Solenoid Valve High Control (A/T) 7 - - Not Used 8 L-BU/WH 1229 PC Solenoid Valve Low Control (A/T) 9 D-GN/ WH 465 Fuel Pump Relay Control 10 WH 121 Engine Speed Signal (Except HP2) L-BU/BK 647 Medium Resolution Engine Speed Signal (HP2) 11-13 - - Not Used 14 RD/BK 380 A/C Refrigerant Pressure Sensor Signal (A/C) 15 BN 25 Charge Indicator Control (20/30 Series) PU 5428 Generator Regulator Control (10 Series except HP2) 16 GY/BK 1694 4WD Low Signal (NP8 or NP1) 17 - - Not Used 18 D-GN 1433 Clutch Start Switch Signal (M/T) 19 BK/WH 1695 Axle Switch Signal (4WD) 20 L-GN/BK 822 VSS Low Signal 21 PU/WH 821 VSS High Signal 22 RD/BK 1230 AT ISS High Signal (MT1) 23 D-BU/ WH 1231 AT ISS Low Signal (MT1) 24 - - Not Used 25 TN 472 IAT Sensor Signal 26 PU 2121 IC 1 Control 27 RD 2127 IC 7 Control 28 L-BU/WH 2126 IC 6 Control 29 D-GN/ WH 2124 IC 4 Control 30 - - Not Used 31 YE 492 MAF Sensor Signal 32 L-GN 432 MAP Sensor Signal 33 D-BU 473 High Speed Cooling Fan Relay Control (10 Series) 34 D-GN/ WH 428 EVAP Canister Purge Solenoid Control 35 WH 121 Engine Speed Signal (HP2) 35-38 - - Not Used 39 RD 631 12-Volt Reference 40 BK/WH 451 Ground 41 - - Not Used 42 TN/BK 422 TCC Solenoid Valve Control (M30/M32/M33) 43 D-GN/ WH 459 A/C Compressor Clutch Relay Control (A/C) 44 - - Not Used 45 WH 1310 EVAP Canister Vent Solenoid Control 46 BN/WH 419 MIL Control 47 YE/BK 1223 2-3 Shift Solenoid Valve Control (A/T) 48 L-GN 1222 1-2 Shift Solenoid Valve Control (A/T) 49 YE/BK 1827 Vehicle Speed Signal 50 D-GN/ WH 817 Vehicle Speed Signal 51 YE/BK 1227 TFT Sensor Signal (A/T) 52 BN 2391 HO2S Heater Low Control Bank 1 Sensor 2 53 RD/WH 3223 HO2S Heater Low Control Bank 2 Sensor 2 54 PU 1589 Fuel Level Sensor Signal - Primary 55-56 - - Not Used 57 BK 552 Low Reference 58 TN/WH 332 Oil Pressure Sensor Signal 59 PU 806 Crank Voltage 60 BN 2129 Low Reference 61 BN/WH 2130 Low Reference 62 GY 773 Transmission Range Switch Signal C (A/T) 63 PK 1224 Transmission Fluid Pressure Switch Signal A (A/T) 64 D-GN 890 Fuel Tank Pressure Sensor Signal 65 - - Not Used 66 PU/WH 2128 IC 8 Control 67 RD/WH 2122 IC 2 Control 68 D-GN 2125 IC 5 Control 69 L-BU 2123 IC 3 Control 70 TN/WH 2500 High Speed GMLAN Serial Data (+) (HP2) 71 TN 2501 High Speed GMLAN Serial Data (-) (HP2) 72 BK/WH 3113 HO2S Heater Low Control Bank 1 Sensor 1 73 D-BU 1936 Fuel Level Sensor Signal - Secondary 74 L-GN 3212 HO2S Heater Low Control Bank 2 Sensor 1 75 GY 23 Generator Field Duty Cycle Signal (Except HP2) 76-79 - - Not Used 80 BK 2751 Low Reference (A/C)
Engine Controls Connector End Views
Accelerator Pedal Position (APP) Sensor Connector Part Information 15318071 10-Way F Metri-Pack 150 Series (GY) Pin Wire Color Circuit No. Function A - - Not Used B PU 1272 5-Volt Reference C L-BU 1162 APP Sensor 2 Signal D TN 1274 Low Reference E BN 1271 Low Reference F D-BU 1161 APP Sensor 1 Signal G WH/BK 1164 5-Volt Reference H-K - - Not Used
Camshaft Position (CMP) Sensor Connector Part Information 12059595 3-Way F Metri-Pack 150 Series (BK) Pin Wire Color Circuit No. Function A BN/WH 633 CMP Sensor Signal B PK/BK 632 Low Reference C RD 631 12-Volt Reference
Crankshaft Position (CKP) Sensor Connector Part Information 15324165 3-Way F Metri-Pack 150 Series (WH) Pin Wire Color Circuit No. Function A D-BU/WH 1869 CKP Sensor Signal B YE/BK 1868 Low Reference C L-GN 1867 12-Volt Reference
Engine Coolant Temperature (ECT) Sensor Connector Part Information 15359366 2-Way F GT 150 Series Sealed (BK) Pin Wire Color Circuit No. Function A BK 407 Low Reference B YE 410 ECT Sensor Signal
Evaporative Emission (EVAP) Canister Purge Solenoid Connector Part Information 12124037 2-Way F Metri-Pack 150 Series (BK) Pin Wire Color Circuit No. Function A PK 439 Ignition 1 Voltage B D-GN/WH 428 EVAP Canister Purge Solenoid Control
Evaporative Emission (EVAP) Canister Vent Solenoid Connector Part Information 12052643 2-Way F Metri-Pack 150 Series Sealed (RD) Pin Wire Color Circuit No. Function A WH 1310 EVAP Canister Vent Solenoid Control B OG 2640 Battery Positive Voltage
Fuel Composition Sensor (L59) Connector Part Information 12146121 3-Way F Metri-Pack 150 Series Sealed (BN) Pin Wire Color Circuit No. Function A WH 1579 Fuel Temperature/Composition Signal B PK 439 Ignition 1 Voltage C BK 550 Ground
Fuel Injector 1 (Except L59) Connector Part Information 15411634 2-Way F Micro-Pack 064 Series (GY) Pin Wire Color Circuit No. Function A PK 1039 Ignition 1 Voltage B BK 1744 Fuel Injector 1 Control
Fuel Injector 1 (L59) Connector Part Information 15355226 2-Way F Metri-Pack 150 Series (BK) Pin Wire Color Circuit No. Function A PK 1039 Ignition 1 Voltage B BK 1744 Fuel Injector 1 Control
Fuel Injector 2 (Except L59) Connector Part Information 15411634 2-Way F Micro-Pack 064 Series (GY) Pin Wire Color Circuit No. Function A PK 1239 Ignition 1 Voltage B L-GN/BK 1745 Fuel Injector 2 Control
Fuel Injector 2 (L59) Connector Part Information 15355226 2-Way F Metri-Pack 150 Series (BK) Pin Wire Color Circuit No. Function A PK 1239 Ignition 1 Voltage B L-GN/BK 1745 Fuel Injector 2 Control
Fuel Injector 3 (Except L59) Connector Part Information 15411634 2-Way F Micro-Pack 064 Series (GY) Pin Wire Color Circuit No. Function A PK 1039 Ignition 1 Voltage B PK/BK 1746 Fuel Injector 3 Control
Fuel Injector 3 (L59) Connector Part Information 15411634 2-Way F Micro-Pack 064 Series (GY) Pin Wire Color Circuit No. Function A PK 1039 Ignition 1 Voltage B PK/BK 1746 Fuel Injector 3 Control
Fuel Injector 4 (Except L59) Connector Part Information 15411634 2-Way F Micro-Pack 064 Series (GY) Pin Wire Color Circuit No. Function A PK 1239 Ignition 1 Voltage B L-BU/BK 844 Fuel Injector 4 Control
Fuel Injector 4 (L59) Connector Part Information 15355226 2-Way F Metri-Pack 150 Series (BK) Pin Wire Color Circuit No. Function A PK 1239 Ignition 1 Voltage B L-BU/BK 844 Fuel Injector 4 Control
Fuel Injector 5 (Except L59) Connector Part Information 15411634 2-Way F Micro-Pack 064 Series (GY) Pin Wire Color Circuit No. Function A PK 1039 Ignition 1 Voltage B BK/WH 845 Fuel Injector 5 Control
Fuel Injector 5 (L59) Connector Part Information 15355226 2-Way F Metri-Pack 150 Series (BK) Pin Wire Color Circuit No. Function A PK 1039 Ignition 1 Voltage B BK/WH 845 Fuel Injector 5 Control
Fuel Injector 6 (Except L59) Connector Part Information 15411634 2-Way F Micro-Pack 064 Series (GY) Pin Wire Color Circuit No. Function A PK 1239 Ignition 1 Voltage B YE/BK 846 Fuel Injector 6 Control
Fuel Injector 6 (L59) Connector Part Information 15355226 2-Way F Metri-Pack 150 Series (BK) Pin Wire Color Circuit No. Function A PK 1239 Ignition 1 Voltage B YE/BK 846 Fuel Injector 6 Control
Fuel Injector 7 (Except L59) Connector Part Information 15411634 2-Way F Micro-Pack 064 Series (GY) Pin Wire Color Circuit No. Function A PK 1039 Ignition 1 Voltage B RD/BK 877 Fuel Injector 7 Control
Fuel Injector 7 (L59) Connector Part Information 15355226 2-Way F Metri-Pack 150 Series (BK) Pin Wire Color Circuit No. Function A PK 1039 Ignition 1 Voltage B RD/BK 877 Fuel Injector 7 Control
Fuel Injector 8 (Except L59) Connector Part Information 15411634 2-Way F Micro-Pack 064 Series (GY) Pin Wire Color Circuit No. Function A PK 1239 Ignition 1 Voltage B D-BU/WH 878 Fuel Injector 8 Control
Fuel Injector 8 (L59) Connector Part Information 15355226 2-Way F Metri-Pack 150 Series (BK) Pin Wire Color Circuit No. Function A PK 1239 Ignition 1 Voltage B D-BU/WH 878 Fuel Injector 8 Control
Fuel Pump (FP) Relay - Secondary (w/Dual Tanks) Connector Part Information 12129716 4-Way F Metri-Pack 280 Series FLX LK (GY) Pin Wire Color Circuit No. Function 30 PK 139 Ignition 1 Voltage 85 GY 120 Fuel Pump Supply Voltage 86 TN 1465 Fuel Pump Relay Control - Secondary 87 L-GN 1058 Fuel Balance Pump Supply Voltage
Fuel Tank Pressure (FTP) Sensor Connector Part Information 12059595 3-Way F Metri-Pack 150 Series (BK) Pin Wire Color Circuit No. Function A BK 470 Low Reference B D-GN 890 Fuel Tank Pressure Sensor Signal C GY 474 5-Volt Reference
Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 (L59/LM7) Connector Part Information 12176897 4-Way F Metri-Pack 150 Series Sealed (GY) Pin Wire Color Circuit No. Function A TN 1664 HO2S Low Signal Bank 1 Sensor 1 B PU/WH 1665 HO2S High Signal Bank 1 Sensor 1 C BK/WH 3113 HO2S Heater Low Control Bank 1 Sensor 1 D PK 539 Ignition 1 Voltage
Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 (LR4) Connector Part Information 15326423 4-Way F Metri-Pack 150 Series Sealed (GY) Pin Wire Color Circuit No. Function A TN 1664 HO2S Low Signal Bank 1 Sensor 1 B PU/WH 1665 HO2S High Signal Bank 1 Sensor 1 C BK/WH 3113 HO2S Heater Low Control Bank 1 Sensor 1 D PK 539 Ignition 1 Voltage
Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 (LQ4) Connector Part Information 12092839 4-Way M Metri-Pack 150 Series (BK) Pin Wire Color Circuit No. Function A TN 1664 HO2S Low Signal Bank 1 Sensor 1 B PU/WH 1665 HO2S High Signal Bank 1 Sensor 1 C - - Not Used D PK 539 Ignition 1 Voltage E BK/WH 3113 HO2S Heater Low Control Bank 1 Sensor 1
Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 (L59/LM7) Connector Part Information 12160482 4-Way F Metri-Pack 150 Series Sealed (GY) Pin Wire Color Circuit No. Function A TN/WH 1669 HO2S Low Signal Bank 1 Sensor 2 B PU/WH 1668 HO2S High Signal Bank 1 Sensor 2 C BN 2391 HO2S Heater Low Control Bank 1 Sensor 2 D PK 1539 Ignition 1 Voltage
Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 (LR4/LQ4) Connector Part Information 15326423 4-Way F Metri-Pack 150 Series Sealed (GY) Pin Wire Color Circuit No. Function A TN/WH 1669 HO2S Low Signal Bank 1 Sensor 2 B PU/WH 1668 HO2S High Signal Bank 1 Sensor 2 C BN 2391 HO2S Heater Low Control Bank 1 Sensor 2 D PK 1539 Ignition 1 Voltage
Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 (L59/LM7) Connector Part Information 12176897 4-Way F Metri-Pack 150 Series (GY) Pin Wire Color Circuit No. Function A TN 1667 HO2S Low Signal Bank 2 Sensor 1 B PU 1666 HO2S High Signal Bank 2 Sensor 1 C L-GN 3212 HO2S Heater Low Control Bank 2 Sensor 1 D PK 539 HO2S High Signal Bank 2 Sensor 1
Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 (LR4) Connector Part Information 15326423 4-Way F Metri-Pack 150 Series (GY) Pin Wire Color Circuit No. Function A TN 1667 HO2S Low Signal Bank 2 Sensor 1 B PU 1666 HO2S High Signal Bank 2 Sensor 1 C L-GN 3212 HO2S Heater Low Control Bank 2 Sensor 1 D PK 539 HO2S High Signal Bank 2 Sensor 1
Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 (LQ4) Connector Part Information 12092839 4-Way F Metri-Pack 150 Series (BK) Pin Wire Color Circuit No. Function A TN 1667 HO2S Low Signal Bank 2 Sensor 1 B PU 1666 HO2S High Signal Bank 2 Sensor 1 C - - Not Used D PK 539 HO2S High Signal Bank 2 Sensor 1 E L-GN 3212 HO2S Heater Low Control Bank 2 Sensor 1
Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 (L59/LM7) Connector Part Information 12176897 4-Way F Metri-Pack 150 Series (GY) Pin Wire Color Circuit No. Function A TN 1671 HO2S Low Signal Bank 2 Sensor 2 B PU 1670 HO2S High Signal Bank 2 Sensor 2 C RD/WH 3223 HO2S Heater Low Control Bank 2 Sensor 2 D PK 1539 Ignition 1 Voltage
Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 (LR4/LQ4) Connector Part Information 15326423 4-Way F Metri-Pack 150 Series (GY) Pin Wire Color Circuit No. Function A TN 1671 HO2S Low Signal Bank 2 Sensor 2 B PU 1670 HO2S High Signal Bank 2 Sensor 2 C RD/WH 3223 HO2S Heater Low Control Bank 2 Sensor 2 D PK 1539 Ignition 1 Voltage
Ignition Coil 1 Connector Part Information 15413116 4-Way F GT 150 Series Sealed (GY) Pin Wire Color Circuit No. Function A BK 550 Ground B BN 2129 Low Reference C PU 2121 IC 1 Control D PK 1039 Ignition 1 Voltage
Ignition Coil 2 Connector Part Information 15413116 4-Way F GT 150 Series Sealed (GY) Pin Wire Color Circuit No. Function A BK 550 Ground B BN 2130 Low Reference C RD 2122 IC 2 Control D PK 1239 Ignition 1 Voltage
Ignition Coil 3 Connector Part Information 15413116 4-Way F GT 150 Series Sealed (GY) Pin Wire Color Circuit No. Function A BK 550 Ground B BN 2129 Low Reference C L-BU 2123 IC 3 Control D PK 1039 Ignition 1 Voltage
Ignition Coil 4 Connector Part Information 15413116 4-Way F GT 150 Series Sealed (GY) Pin Wire Color Circuit No. Function A BK 550 Ground B BN 2130 Low Reference C D-GN 2124 IC 4 Control D PK 1239 Ignition 1 Voltage
Ignition Coil 5 Connector Part Information 15413116 4-Way F GT 150 Series Sealed (GY) Pin Wire Color Circuit No. Function A BK 550 Ground B BN 2129 Low Reference C D-GN 2125 IC 5 Control D PK 1039 Ignition 1 Voltage
Ignition Coil 6 Connector Part Information 15413116 4-Way F GT 150 Series Sealed (GY) Pin Wire Color Circuit No. Function A BK 550 Ground B BN 2130 Low Reference C L-BU 2126 IC 6 Control D PK 1239 Ignition 1 Voltage
Ignition Coil 7 Connector Part Information 15413116 4-Way F GT 150 Series Sealed (GY) Pin Wire Color Circuit No. Function A BK 550 Ground B BN 2129 Low Reference C RD 2127 IC 7 Control D PK 1039 Ignition 1 Voltage
Ignition Coil 8 Connector Part Information 15413116 4-Way F GT 150 Series Sealed (GY) Pin Wire Color Circuit No. Function A BK 550 Ground B BN 2130 Low Reference C PU 2128 IC 8 Control D PK 1239 Ignition 1 Voltage
Knock Sensor (KS) - 1 Connector Part Information 12103023 1-Way TRW (GY) Pin Wire Color Circuit No. Function A D-BU 496 Knock Sensor 1 Signal
Knock Sensor (KS) - 2 Connector Part Information 12103023 1-Way TRW (GY) Pin Wire Color Circuit No. Function A L-BU 1876 Knock Sensor 2 Signal
Manifold Absolute Pressure (MAP) Sensor Connector Part Information 12129946 3-Way F Metri-Pack 150 Series (GY) Pin Wire Color Circuit No. Function A OG/BK 469 Low Reference B L-GN 432 MAP Sensor Signal C GY 597 5-Volt Reference
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Part Information 15305555 5-Way F Metri-Pack 150 Series (BK) Pin Wire Color Circuit No. Function A BK 552 Low Reference B TN 472 IAT Sensor Signal C BK/WH 451 Ground D PK 439 Ignition 1 Voltage E YE 492 MAF Sensor Signal
Throttle Actuator Control (TAC) Module C1 Connector Part Information 12191065 16-Way F Micro-Pack 100 Series (GY) Pin Wire Color Circuit No. Function 1 D-GN 485 TP Sensor 1 Signal 2 GY 416 5-Volt Reference 3 BK 452 Low Reference 4 D-BU 84 Cruise Control Set/Coast Switch Signal 5 GY/BK 87 Cruise Control Resume/Accel Switch Signal 6 L-BU 1320 CHMSL Supply Voltage 7 PK 1339 Ignition 1 Voltage 8 BN 582 TAC Motor Control - 2 9 L-BU/BK 1688 5-Volt Reference 10 BK/WH 1704 Low Reference 11 PU 486 TP Sensor 2 Signal 12 OG/BK 1061 UART Serial Data 13 D-BU/WH 774 UART Serial Data 14 GY 397 Cruise Control On Switch Signal 15 BK 550 Ground 16 YE 581 TAC Motor Control - 1
Throttle Actuator Control (TAC) Module C2 Connector Part Information 12177081 10-Way F Metri-Pack 150 Series (BK) Pin Wire Color Circuit No. Function A - - Not Used B PU 1272 5-Volt Reference C L-BU 1162 APP Sensor 2 Signal D TN 1274 Low Reference E - - Not Used F D-BU 1161 APP Sensor 1 Signal G WH/BK 1164 5-Volt Reference H Not Used J BN 1271 Low Reference K - - Not Used
Throttle Body Connector Part Information 15326836 8-Way F GT 150 Series Sealed (BK) Pin Wire Color Circuit No. Function A YE 581 TAC Motor Control - 1 B BK/WH 1704 Low Reference C BN 582 TAC Motor Control - 2 D BK 452 Low Reference E L-BU/BK 1688 5-Volt Reference F PU 486 TP Sensor 2 Signal G D-GN 485 TP Sensor 1 Signal H GY 416 5-Volt Reference
Powertrain Control Module (PCM) Replacement
Service of the powertrain control module (PCM) should consist of either replacement of the PCM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the PCM to be replaced, the replacement PCM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM.
Removal Procedure
| IMPORTANT | To prevent internal PCM damage, the ignition switch must be OFF when disconnecting or connecting power to the PCM. Remove any debris from around the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. The replacement PCM must be programmed. |
- Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life.
- Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-197347-S01049574002005101100000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-197347-S39973143602005101100000) in Engine Electrical.
- If equipped with regular production option (RPO) NYS, remove the harness ground clip from the PCM cover.
- If equipped with RPO HP2, remove the hybrid control module (HCM). Refer to «Hybrid Control Module (HCM) Replacement (5.3L Engine w/RPO HP2)»(ref-197347-S04884276142005101100000) in Engine Electrical.
- If vehicle is NOT equipped with RPO HP2, perform the following: Release the PCM cover mounting tabs. Release the PCM cover from the mounting bracket. Remove the PCM cover.
- If vehicle is equipped with RPO HP2, perform the following: Release the PCM cover mounting tabs. Release the PCM cover from the mounting bracket. Remove the PCM cover.
- Loosen the PCM electrical connector bolts (2).
- Disconnect the PCM electrical connectors.
- Release the spring latch from the PCM.
- Release the PCM mounting tabs from the PCM.
- Remove the PCM.
Installation Procedure
- Install the PCM. Ensure that the mounting tabs are engaged.
- Secure the spring latch to the PCM.
- Connect the PCM electrical connectors.
- Tighten the PCM electrical connector bolts (2). Tighten: Tighten the bolts to 8 N.m (71 lb in).
- If vehicle is equipped with RPO HP2, install the PCM cover.
- If vehicle is NOT equipped with RPO HP2, install the PCM cover.
- If equipped with RPO HP2, install the HCM. Refer to «Hybrid Control Module (HCM) Replacement (5.3L Engine w/RPO HP2)»(ref-197347-S04884276142005101100000) in Engine Electrical.
- If equipped with RPO NYS, install the harness ground clip to the PCM cover.
- Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-197347-S01049574002005101100000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-197347-S39973143602005101100000) in Engine Electrical.
- If a NEW PCM was installed, program the PCM. Refer to «Control Module References»(ref-197326-S18267990112005101100000) in Computer/Integrating Systems.
- Disconnect the instrument panel (I/P) harness electrical connector (2).
- Release the red connector position assurance (CPA) retainer.
- Disconnect the engine wiring harness electrical connector (1).
- Remove the throttle actuator control (TAC) module nuts.
- Remove the TAC module.
- Install the TAC module.
- Install the TAC module nuts. Tighten: Tighten the nuts to 9 N.m (80 lb in).
- Connect the engine wiring harness electrical connector (1).
- Install the red CPA retainer.
- Connect the I/P harness electrical connector (2).
CKP System Variation Learn Procedure
- Install a scan tool.
- Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(ref-197324-S09956880762005101100000) in Vehicle DTC Information for the applicable DTC.
- Select the crankshaft position variation learn procedure with a scan tool.
- The scan tool instructs you to perform the following: Accelerate to wide open throttle (WOT). Release throttle when fuel cut-off occurs. Observe fuel cut-off for applicable engine. Engine should not accelerate beyond calibrated RPM value. Release throttle immediately if value is exceeded. Block drive wheels. Set parking brake. DO NOT apply brake pedal. Cycle ignition from OFF to ON. Apply and hold brake pedal. Start and idle engine. Turn the A/C OFF. Vehicle must remain in Park or Neutral. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC. Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC. Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature.
- Enable the CKP system variation learn procedure with the scan tool.
- Accelerate to WOT.
- Release throttle when fuel cut-off occurs.
- The scan tool display reads Test In Progress.
- The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to «DTC P0315»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-dtc-p0136-to-p0358) . If any other DTCs set, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(ref-197324-S09956880762005101100000) in Vehicle DTC Information for the applicable DTC.
- Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully.
- The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether or not DTC P0315 is set: An engine replacement A PCM replacement A harmonic balancer replacement A crankshaft replacement A CKP sensor replacement Any engine repairs which disturb the crankshaft to CKP sensor relationship.
Note. Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.
- Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to «Draining and Filling Cooling System (w/RPO HP2)»(ref-197356-S32653343972005101100000) or «Draining and Filling Cooling System (w/o RPO HP2)»(ref-197356-S16321664992005101100000) in Engine Cooling.
- Disconnect the ECT sensor electrical connector (5).
- Remove the ECT sensor.
Note. Replacement 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.
Note. Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.
- If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent.
- Install the ECT sensor. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
- Connect the ECT sensor electrical connector (5).
- Refill the cooling. Refer to «Draining and Filling Cooling System (w/RPO HP2)»(ref-197356-S32653343972005101100000) or «Draining and Filling Cooling System (w/o RPO HP2)»(ref-197356-S16321664992005101100000) in Engine Cooling.
| IMPORTANT | Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. |
- Remove the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Pull out the gray connector position assurance (CPA) retainer.
- Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4).
- Loosen the MAF/IAT clamp.
- Remove the MAF/IAT sensor from the air cleaner assembly.
| IMPORTANT | The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. |
- Locate the air flow direction arrow (2) on the MAF/IAT sensor.
- Install the MAF/IAT sensor to the air cleaner assembly.
- Tighten the MAF/IAT clamp. Tighten: Tighten the clamp to 7 N.m (62 lb in).
- Connect the MAF/IAT sensor electrical connector (4).
- Push in the gray CPA retainer.
- Install the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Remove the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L (RPO LQ4))»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/mechanical/#engine-mechanical-48l-53l-60l-repair-instructions-1-of-3) or «Engine Sight Shield Replacement (6.0L (RPO LQ9))»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/mechanical/#engine-mechanical-48l-53l-60l-repair-instructions-1-of-3) in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
- Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1).
- Remove the MAP sensor (1).
| IMPORTANT | Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. |
- Install the MAP sensor (1).
- Connect the MAP sensor electrical connector (1).
- Install the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L (RPO LQ4))»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/mechanical/#engine-mechanical-48l-53l-60l-repair-instructions-1-of-3) or «Engine Sight Shield Replacement (6.0L (RPO LQ9))»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/mechanical/#engine-mechanical-48l-53l-60l-repair-instructions-1-of-3) in Engine Mechanical-4.8L, 5.3L, and 6.0L.
- Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197364-S02039416942005101100000) in General Information.
- If necessary, unbolt the front propeller shaft from the front differential. Refer to «Propeller Shaft Replacement - Front»(ref-197434-S11772894682005101100000) in Propeller Shaft.
- Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to «HEATED OXYGEN AND OXYGEN SENSOR NOTICE»(ref-197335-S23271906062005101100000) in Cautions and Notices.
- Remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip.
- If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (1).
- If equipped with a 6.0L engine, disconnect the HO2S electrical connector (1).
- Remove the HO2S.
| IMPORTANT | A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. |
- If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
- Install the HO2S. Tighten: Tighten the sensor to 42 N.m (31 lb ft).
- If equipped with a 6.0L engine, connect the HO2S electrical connector (1).
- If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (1).
- Install the HO2S electrical connector to the fuel line clip.
- Disconnect the CPA retainer.
- If necessary, bolt the front propeller shaft to the front differential. Refer to «Propeller Shaft Replacement - Front»(ref-197434-S11772894682005101100000) in Propeller Shaft.
- Lower the vehicle.
- Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197364-S02039416942005101100000) in General Information.
- If equipped, disconnect the fuel composition sensor electrical connector.
- Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to «HEATED OXYGEN AND OXYGEN SENSOR NOTICE»(ref-197335-S23271906062005101100000) in Cautions and Notices.
- If equipped with a fuel composition sensor, remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip.
- If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (2).
- If equipped with a 6.0L engine, disconnect the HO2S electrical connector (2).
- Remove the HO2S.
| IMPORTANT | A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. |
- If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
- Install the HO2S. Tighten: Tighten the sensor to 42 N.m (31 lb ft).
- If equipped with a 6.0L engine, connect the HO2S electrical connector (2).
- If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (2).
- If equipped with a fuel composition sensor, install the HO2S electrical connector to the fuel line clip.
- Disconnect the CPA retainer.
- If equipped, connect the fuel composition sensor electrical connector.
- Lower the vehicle.
- Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197364-S02039416942005101100000) in General Information.
- Disconnect the connector position assurance (CPA) retainer.
- Remove the heated oxygen sensor (HO2S) from the clips NOTE: Refer to «HEATED OXYGEN AND OXYGEN SENSOR NOTICE»(ref-197335-S23271906062005101100000) in Cautions and Notices.
- If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector.
- If equipped with a 6.0L engine, disconnect the HO2S electrical connector.
- Remove the HO2S.
| IMPORTANT | A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. |
- If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
- Install the HO2S. Tighten: Tighten the sensor to 42 N.m (31 lb ft).
- If equipped with a 6.0L engine, connect the HO2S electrical connector.
- If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector.
- Install the HO2S to the clips
- Disconnect the CPA retainer.
- Lower the vehicle.
- Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197364-S02039416942005101100000) in General Information.
- Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to «HEATED OXYGEN AND OXYGEN SENSOR NOTICE»(ref-197335-S23271906062005101100000) in Cautions and Notices.
- Remove the heated oxygen sensor (HO2S) connector clip from the frame.
- If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector.
- If equipped with a 6.0L engine, disconnect the HO2S electrical connector.
- Remove the HO2S.
| IMPORTANT | A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. |
- If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
- Install the HO2S. Tighten: Tighten the sensor to 42 N.m (31 lb ft).
- If equipped with a 6.0L engine, connect the HO2S electrical connector.
- If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector.
- Install the HO2S connector clip to the frame.
- Disconnect the CPA retainer.
- Lower the vehicle.
- Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197364-S02039416942005101100000) in General Information.
- Disconnect the fuel composition sensor electrical connector.
- Remove the fuel line retainers (1).
- Disconnect the fuel composition sensor fuel lines. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Remove the fuel composition sensor bracket nuts.
- Remove the fuel composition sensor.
- If required, remove the fuel composition sensor bolts and remove the sensor from the bracket.
- If required, install the fuel composition sensor to the bracket and install the bolts. Tighten: Tighten bolts to 10 N.m (89 lb in).
- Install the fuel composition sensor.
- Install the fuel composition sensor bracket nuts. Tighten: Tighten nuts to 17 N.m (13 lb ft).
- Connect the fuel composition sensor fuel lines. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Install the fuel line retainers (1).
- Connect the fuel composition sensor electrical connector.
- Lower the vehicle.
- Use the following procedure in order to inspect for leaks: 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. Inspect for fuel leaks.
Note. Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type.
- Remove the connector position assurance (CPA) retainer.
- Disconnect the accelerator pedal position (APP) sensor electrical connector.
- Reposition the carpet to access the lower nut.
- Remove the accelerator pedal nuts.
- Remove the accelerator pedal assembly.
- Install the accelerator pedal assembly.
- Install the accelerator pedal nuts. Tighten: Tighten the nuts to 20 N.m (15 lb ft).
- Connect the APP sensor electrical connector.
- Reposition the carpet.
- Connect a scan tool in order to test for proper throttle-opening and throttle-closing range.
- Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT).
- Verify that the vehicle meets the following conditions: The vehicle is not in a reduced engine power mode. The ignition is ON. The engine is OFF.
- Inspect the carpet fit under the accelerator pedal.
Note. Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type.
| IMPORTANT | DO NOT for any reason, insert a screwdriver or other small hand tools into the throttle body to hold open the throttle plate, as the wedge inside the throttle body could be damaged. An 8-digit part identification number is stamped on the throttle body casting. Refer to this number if servicing, or part replacement is required. |
- Partially drain the cooling system in order to allow the hose at the throttle body to be removed. Refer to «Draining and Filling Cooling System (w/RPO HP2)»(ref-197356-S32653343972005101100000) or «Draining and Filling Cooling System (w/o RPO HP2)»(ref-197356-S16321664992005101100000) in Engine Cooling.
- Remove the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Remove the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L (RPO LQ4))»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/mechanical/#engine-mechanical-48l-53l-60l-repair-instructions-1-of-3) or «Engine Sight Shield Replacement (6.0L (RPO LQ9))»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/mechanical/#engine-mechanical-48l-53l-60l-repair-instructions-1-of-3) in Engine Mechanical-4.8L, 5.3L, and 6.0L.
- Disconnect the throttle actuator motor electrical connector (2).
- Reposition the coolant air bleed hose clamp at the throttle body.
- Remove the coolant air bleed hose from the throttle body.
- Remove the throttle body nuts.
- Remove the throttle body.
- Remove and discard the throttle body gasket.
- Install the NEW throttle body gasket.
- Install the throttle body.
- Install the throttle body nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
- Install the coolant air bleed hose to the throttle body.
- Position the coolant air bleed hose clamp at the throttle body.
- Connect the throttle actuator motor electrical connector (2).
- Install the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L (RPO LQ4))»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/mechanical/#engine-mechanical-48l-53l-60l-repair-instructions-1-of-3) or «Engine Sight Shield Replacement (6.0L (RPO LQ9))»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/mechanical/#engine-mechanical-48l-53l-60l-repair-instructions-1-of-3) in Engine Mechanical-4.8L, 5.3L, and 6.0L.
- Install the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Refill the cooling system. Refer to «Draining and Filling Cooling System (w/RPO HP2)»(ref-197356-S32653343972005101100000) or «Draining and Filling Cooling System (w/o RPO HP2)»(ref-197356-S16321664992005101100000) in Engine Cooling.
- Connect a scan tool in order to test for proper throttle-opening and throttle-closing range.
- Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT).
- Verify that the vehicle meets the following conditions: The vehicle is not in a reduced engine power mode. The ignition is ON. The engine is OFF.
- Start the engine.
- Inspect for coolant leaks.
Throttle Body Cleaning Procedure
- Remove the air cleaner intake duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) . CAUTION: Turn OFF the ignition before inserting fingers into the throttle bore. Unexpected movement of the throttle blade could cause personal injury. NOTE: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate.
- Inspect the throttle body bore and the throttle plate for deposits. You will need to open the throttle plate in order to inspect all surfaces. NOTE: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components.
- Clean the throttle body bore and the throttle plate using a clean shop towel with GM Top Engine Cleaner, P/N 1052626 or AC-Delco Carburetor Tune-Up Conditioner, P/N X66-P, or an equivalent product.
- Install the air cleaner intake duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
Tools Required
J 34730-1A Fuel Pressure Gage
| CAUTION | Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. |
- Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-197347-S01049574002005101100000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-197347-S39973143602005101100000) in Engine Electrical.
- Install the J 34730-1A . Refer to «Fuel Pressure Gage Installation and Removal»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Loosen the fuel fill cap in order to relieve fuel tank vapor pressure.
- Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing.
- Drain any fuel remaining in the gage into an approved container.
- Once the system pressure is completely relieved, remove the J 34730-1A .
J 34730-1A Fuel Pressure Gage
| CAUTION | Refer to GASOLINE/GASOLINE VAPORS CAUTION in Cautions and Notices. |
| CAUTION | Refer to FUEL GAGE LEAK CAUTION in Cautions and Notices. |
- Remove the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L (RPO LQ4))»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/mechanical/#engine-mechanical-48l-53l-60l-repair-instructions-1-of-3) or «Engine Sight Shield Replacement (6.0L (RPO LQ9))»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/mechanical/#engine-mechanical-48l-53l-60l-repair-instructions-1-of-3) in Engine Mechanical-4.8L, 5.3L, and 6.0L.
- Remove the fuel rail pressure fitting cap.
- Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage.
- Install the bleed hose on J 34730-1A into an approved container.
- Remove the bleed hose on the J 34730-1A from the approved container.
- Remove the shop towel from around the fitting and discard into an approved container.
- Disconnect the J 34730-1A from the fuel pressure valve.
- Install the fuel rail pressure fitting cap.
- Install the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L (RPO LQ4))»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/mechanical/#engine-mechanical-48l-53l-60l-repair-instructions-1-of-3) or «Engine Sight Shield Replacement (6.0L (RPO LQ9))»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/mechanical/#engine-mechanical-48l-53l-60l-repair-instructions-1-of-3) in Engine Mechanical-4.8L, 5.3L, and 6.0L.
Quick Connect Fitting(s) Service (Metal Collar)
Tools Required
- J 41769 Fuel Line Quick Disconnect Tool
- J 43178 Fuel Line Disconnect Tool. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) .
- Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-81l-introduction) .
- Remove the retainer from the fuel feed line to engine quick-connect fitting.
- If equipped with the 5.3L (L59) engine, remove the retainers from the fuel feed and return line to engine quick-connect fittings.
- Using compressed air, blow any dirt or debris from around the fitting.
- Using the correct tool from J 41769 , insert the tool into the female connector, then push inward in order to release the quick connect locking tabs.
- If the vehicle is a cab/chassis, it may be necessary to use J 43178 in order to release the quick connect locking tabs. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) .
- Pull the fuel line connection apart.
- Use a clean shop towel in order to wipe off the male connection end.
- Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required.
- Apply a few drops of clean engine oil to the male connection end.
- Push both sides of the fittings together in order to snap the retaining tabs into place.
- Once installed, pull on both sides of the connection in order to make sure the connection is secure.
- If equipped with the 5.3L (L59) engine, install the retainers to the fuel feed and return line to engine quick-connect fittings.
- Install the retainer to the fuel feed line quick-connect fitting.
- Install the fuel fill cap.
- Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-197347-S01049574002005101100000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-197347-S39973143602005101100000) in Engine Electrical.
| IMPORTANT | There are several types of plastic fuel and evaporative emission (EVAP) quick connect fittings used on this vehicle. The following instructions apply to all types of plastic quick connect fittings except where indicated. |
- Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Using compressed air, blow any dirt or debris from around the quick connect fitting.
- Squeeze the plastic quick connect fitting release tabs together to disengage the quick connect fitting. (This step applies to Bartholomew style fittings ONLY)
- Squeeze where indicated by the arrows on both sides of the plastic ring to disengage the quick connect fitting.
- Squeeze where indicated by the arrows on both sides of the plastic ring to disengage the quick connect fitting.
- Pull the quick connect fitting connection apart.
- Apply a few drops of clean engine oil to the male connection end.
- Push both sides of the quick-connect fitting together in order to cause the retaining tabs to snap into place.
- Once installed, pull on both sides of the quick-connect fittings in order to make sure the connection is secure.
J 45004 Fuel Tank Siphon Hose. See Special Tools .
| CAUTION | Refer to GASOLINE/GASOLINE VAPORS CAUTION in Cautions and Notices. |
- Remove the fuel fill cap.
- Insert the adapter to the fill pipe in order to hold open the internal fill pipe door.
- Insert the J 45004 hose through the adapter and into the tank. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) .
- Attach the J 45004 hose to the hose used with the hand or air operated pumping device. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) .
- Using the hand or air operated pumping device, drain as much fuel from the tank as possible.
Fuel Tank Draining Procedure (5.3L - L59 Engine)
| CAUTION | Refer to GASOLINE/GASOLINE VAPORS CAUTION in Cautions and Notices. |
- Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure.
- Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197364-S02039416942005101100000) in General Information.
- Loosen the fuel tank fill pipe clamp (3) at the fuel tank.
- Remove the fuel tank fill pipe.
- Remove the flame arrester screen from the tank opening.
- Insert a hose into the fuel tank opening.
- Using a hand or air operated pumping device, drain as much fuel from the tank as possible.
| IMPORTANT | Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. |
- Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Drain the fuel tank. Refer to «Fuel Tank Draining Procedure (4.8L, 5.3L, and 6.0L Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Draining Procedure (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__fuel-tank-draining-procedure-53l) .
- Remove the fuel tank fill pipe. Refer to «Filler Tube Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Filler Tube Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Filler Tube Replacement (Cab/Chassis - Front)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Filler Tube Replacement (Cab/Chassis - Rear)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Remove the EVAP canister vent solenoid. Refer to «Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (Cab/Chassis)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Remove the fuel tank shield bolts, if equipped.
- Remove the fuel tank shield, if equipped.
- Disconnect the fuel feed and EVAP lines. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Cap the fuel and EVAP lines in order to prevent possible system contamination.
- Place a suitable adjustable jack under the fuel tank.
- Remove the fuel tank strap bolts.
- Remove the fuel tank straps.
- Lower the fuel tank half way. When lowering the tank, ensure that the fill neck on the tank does not get hung up on the harness.
- Disconnect the electrical harness clip at the frame crossmember.
- Lower the fuel tank until the electrical connections are accessible.
- Disconnect the fuel pressure sensor electrical connector.
- Disconnect the fuel sending unit electrical connector, perform the following: Disengage the gray retainer. Push down the black clip. Disconnect the connector.
- Completely lower the fuel tank.
- With the aid of an assistant, place the fuel tank in a suitable work area.
- If necessary, disconnect and remove the fuel feed line (1) from the sending unit and retaining clips.
- If necessary, disconnect and remove the EVAP purge line (2) from the retaining clips.
- If necessary, disconnect and remove the EVAP fuel level vent valve (FLVV) line from the FLVV, sending unit, and retaining clips.
- If necessary, remove the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- If necessary, install the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- If necessary, install and connect the EVAP FLVV line to the FLVV, sending unit, and retaining clips.
- If necessary, install and connect the EVAP purge line (2) to the retaining clips.
- If necessary, install and connect the fuel feed line (1) to the sending unit and retaining clips.
- With the aid of an assistant, place the fuel tank onto the adjustable jack.
- Raise the fuel tank until the electrical connections can be made.
- Connect the fuel sending unit and pressure sensor electrical connectors.
- Completely raise the fuel tank. When raising the tank, ensure that the fill neck on the tank goes over the harness.
- Install the fuel tank straps.
- Install the fuel tank strap bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
- Remove the adjustable jack from under the fuel tank.
- Remove the caps from the fuel and EVAP lines.
- Connect the fuel feed and EVAP lines. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- If necessary, install the fuel tank shield.
- If necessary, install the fuel tank shield bolts. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
- Install the EVAP canister vent solenoid. Refer to «Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (Cab/Chassis)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Install the fuel tank fill pipe. Refer to «Filler Tube Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Filler Tube Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Filler Tube Replacement (Cab/Chassis - Front)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Filler Tube Replacement (Cab/Chassis - Rear)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Refill the fuel tank.
- Install the fuel cap.
- Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-197347-S01049574002005101100000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-197347-S39973143602005101100000) in Engine Electrical.
- Perform the following procedure in order to inspect for leaks: 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. Inspect for fuel leaks.
- Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Drain the fuel tank. Refer to «Fuel Tank Draining Procedure (4.8L, 5.3L, and 6.0L Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Draining Procedure (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__fuel-tank-draining-procedure-53l) .
- Remove the fuel tank fill pipe. Refer to «Filler Tube Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Filler Tube Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Filler Tube Replacement (Cab/Chassis - Front)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Filler Tube Replacement (Cab/Chassis - Rear)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Remove the fuel tank shield bolts and shield, if necessary.
- Remove the evaporative emission (EVAP) canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect the fuel feed line from the tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Cap the fuel and EVAP lines in order to prevent possible system contamination.
- Place an adjustable jack under the fuel tank.
- Remove the fuel tank strap bolts.
- Remove the fuel tank straps.
- Remove the harness clip from the frame.
- Lower the fuel tank under the electrical connectors are accessible.
- Disconnect the fuel tank pressure sensor (1) electrical connector.
- Disconnect the fuel tank sending unit (2) electrical connector, perform the following: Disengage the gray retainer. Push down the black clip. Disconnect the connector.
- Completely lower the fuel tank.
- With the aid of an assistant, place the fuel tank in a suitable work area.
- If necessary, remove the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- If necessary, install the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- With the aid of an assistant, place the fuel tank on a adjustable jack.
- Raise the fuel tank until the electrical connections can be made.
- Connect the fuel tank sending unit (2) electrical connector. Engage the gray retainer.
- Connect the fuel tank pressure sensor (1) electrical connector.
- Completely raise the fuel tank.
- Install the harness clip to the frame.
- Install the fuel tank straps.
- Install the fuel tank strap bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
- Remove the adjustable jack from under the fuel tank.
- Remove the caps from the fuel and EVAP lines.
- Connect the fuel feed line at the tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Install the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Install the fuel tank shield and bolts, if necessary. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
- Install the fuel tank fill pipe. Refer to «Filler Tube Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Filler Tube Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Filler Tube Replacement (Cab/Chassis - Front)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Filler Tube Replacement (Cab/Chassis - Rear)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Refill the fuel tank.
- Install the fuel cap.
- Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-197347-S01049574002005101100000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-197347-S39973143602005101100000) in Engine Electrical.
- Perform the following procedure in order to inspect for leaks: 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. Inspect for fuel leaks.
| IMPORTANT | Clean the fuel and evaporative emission (EVAP) connections and surrounding area prior to disconnecting the lines in order to avoid possible system contamination. |
- Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- If equipped with a rear auxiliary tank, disconnect the fuel feed and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Cap the fuel feed and EVAP pipes in order to prevent possible system contamination.
- Loosen the fuel fill pipe clamp (2) at the tank.
- Loosen the vent pipe clamp (1) at the tank.
- Remove the fuel fill pipe and vent pipe from the tank.
- Drain the fuel tank. Refer to «Fuel Tank Draining Procedure (4.8L, 5.3L, and 6.0L Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Draining Procedure (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__fuel-tank-draining-procedure-53l) .
- Disconnect the fuel pressure sensor electrical connector (1).
- Disconnect the fuel sending unit electrical connector (1), perform the following: Disengage the gray retainer. Push down the black clip. Disconnect the connector.
- Remove the canister vent solenoid (CVS) line from the fuel tank clips.
- Disconnect the fuel feed and EVAP quick connect fittings from the sending unit. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197364-S02039416942005101100000) in General Information.
- Remove the fuel tank shield bolts.
- Remove the fuel tank shield.
- Place a suitable adjustable jack under the fuel tank.
- Remove the fuel tank strap bolts.
- Remove the fuel tank straps.
- Lower the fuel tank.
- With the aid of an assistant, place the fuel tank in a suitable work area.
- Cap the fuel and EVAP pipes in order to prevent possible system contamination.
- If necessary, remove the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- If necessary, install the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Remove the caps from the fuel and EVAP pipes.
- With the aid of an assistant, place the fuel tank on the jack.
- Raise the fuel tank.
- Install the fuel tank straps. NOTE: Refer to «Fastener Notice»(ref-197335-S17275608472005101100000) in Cautions and Notices.
- Install the fuel tank strap bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
- Remove the jack from under the fuel tank.
- Install the fuel tank shield.
- Install the fuel tank shield bolts. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
- Lower the vehicle.
- Connect the fuel feed and EVAP quick connect fittings to the sending unit. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Connect the fuel sending unit and fuel pressure sensor electrical connectors (1).
- Install the CVS line to the fuel tank clips.
- Install the fuel fill pipe and vent pipe to the tank.
- Tighten the vent pipe clamp (1) at the tank.
- Tighten the fuel fill pipe clamp (2) at the tank. Tighten: Tighten the clamps to 2.5 N.m (22 lb in).
- Remove the caps from the fuel feed and EVAP pipes.
- If equipped with a rear auxiliary tank, connect the fuel feed and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Refill the fuel tank.
- Install the fuel fill cap.
- Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-197347-S01049574002005101100000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-197347-S39973143602005101100000) .
- Perform the following steps in order to inspect for leaks. 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. Inspect for fuel leaks.
| IMPORTANT | Clean the fuel and evaporative emission (EVAP) connections and surrounding area prior to disconnecting the lines in order to avoid possible system contamination. |
- Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Loosen the fuel fill pipe hose clamp (2) at the tank.
- Loosen the fuel vent pipe hose clamp (1) at the tank.
- Remove the fuel fill and vent hoses from the tank.
- Drain the fuel tank. Refer to «Fuel Tank Draining Procedure (4.8L, 5.3L, and 6.0L Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Draining Procedure (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__fuel-tank-draining-procedure-53l) .
- Disconnect the fuel tank pressure sensor electrical connector.
- Disconnect the fuel feed and EVAP (evaporative emission) quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Cap the fuel/EVAP lines in order to prevent possible system contamination.
- Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197364-S02039416942005101100000) in General Information.
- Remove the fuel tank shield bolts.
- Remove the fuel tank shield.
- Place a suitable adjustable jack under the fuel tank.
- Remove the fuel tank strap bolts.
- Remove the fuel tank straps.
- Lower the fuel tank.
- With the aid of an assistant, place the fuel tank in a suitable work area.
- If necessary, remove the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- If necessary, install the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- With the aid of an assistant, place the fuel tank on the jack.
- Raise the fuel tank.
- Install the fuel tank straps. NOTE: Refer to «Fastener Notice»(ref-197335-S17275608472005101100000) in Cautions and Notices.
- Install the fuel tank strap bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
- Remove the jack from under the fuel tank.
- Install the fuel tank shield.
- Install the fuel tank shield bolts. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
- Lower the vehicle.
- Remove the caps from the fuel/EVAP lines.
- Connect the fuel feed and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Connect the fuel tank pressure sensor electrical connector.
- Install the fuel fill and vent hoses to the tank.
- Tighten the fuel vent pipe hose clamp (1) at the tank.
- Tighten the fuel fill pipe hose clamp (2) at the tank. Tighten: Tighten the clamps to 2.5 N.m (22 lb in).
- Refill the fuel tank.
- Install the fuel fill cap.
- Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-197347-S01049574002005101100000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-197347-S39973143602005101100000) in Engine Electrical.
- Perform the following steps in order to inspect for leaks. 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. Inspect for fuel leaks.
- Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Front)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Using a slight rocking motion, while pulling straight up, remove the fuel tank pressure sensor (1).
- Install the fuel tank pressure sensor (1).
- Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Front)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Remove the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect the fuel pump electrical connector.
- Remove the fuel lever sensor electrical connector retaining clip.
- Disconnect the fuel level sensor electrical connector.
- Remove the fuel level sensor retaining clip.
- Remove the fuel level sensor (1).
- Install the fuel level sensor (1).
- Install the fuel level sensor retaining clip.
- Connect the fuel level sensor electrical connector.
- Install the fuel lever sensor electrical connector retaining clip.
- Connect the fuel pump electrical connector.
- Install the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Remove the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect the fuel pump electrical connector.
- Remove the fuel level sensor electrical connector retaining clip.
- Disconnect the fuel level sensor electrical connector.
- Remove the fuel level sensor retaining clip.
- Remove the fuel level sensor.
- Install the fuel level sensor.
- Install the fuel level sensor retaining clip.
- Connect the fuel level sensor electrical connector.
- Install the fuel level sensor electrical connector retaining clip.
- Connect the fuel pump electrical connector.
- Install the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Remove the fuel tank filler housing to body TORX® screws (1) and pushpin retainer (2).
- Remove the fuel tank filler housing to fuel tank fill pipe bolts.
- Remove the fuel tank filler housing.
- Raise and suitably support the vehicle half way. Refer to «Lifting and Jacking the Vehicle»(ref-197364-S02039416942005101100000) in General Information.
- Remove the fuel tank fill pipe ground wire bolt (1).
- Remove the fuel tank fill pipe ground wire (3) anti-rotation tab from the frame hole.
- Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (2).
- Open the axle vent hose clip on the fuel fill pipe bracket.
- Remove the rear axle vent hose from the clip.
- Loosen the fuel tank fill pipe clamp (1) at the fuel tank.
- Disconnect the recirculation line from the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Remove the fuel tank fill pipe.
- Cap the opening on the fuel tank in order to prevent possible system contamination.
- Remove the cap from the opening on the fuel tank.
- Install the fuel tank fill pipe.
- Connect the recirculation line to the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) . NOTE: Refer to «Fastener Notice»(ref-197335-S17275608472005101100000) in Cautions and Notices.
- Tighten the fuel tank fill pipe clamp (1) at the fuel tank. Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
- Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
- Close the axle vent hose clip.
- Position the fuel tank fill pipe ground wire and chassis harness ground wire (2).
- Install the fuel tank fill pipe ground wire (3) anti-rotation tab into the frame hole.
- Install the fuel tank fill pipe ground wire bolt (1). Tighten: Tighten the bolt to 9 N.m (80 lb in).
- Lower the vehicle.
- Install the fuel tank filler housing.
- Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten: Tighten the screws to 2.3 N.m (20 lb in).
- Install the fuel tank filler housing to body TORX® screws (1) and pushpin retainer (2). Tighten: Tighten the screws to 2.3 N.m (20 lb in).
- Remove the fuel tank filler housing to body TORX® screws (1) and retainer (2).
- Remove the fuel tank filler housing to fuel tank fill pipe bolts.
- Remove the fuel tank filler housing.
- Partially raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197364-S02039416942005101100000) in General Information.
- Remove the fuel tank fill pipe ground wire bolt.
- Remove the fuel tank fill pipe ground wire from the frame.
- Loosen the fuel tank fill pipe clamp at the fuel tank.
- Disconnect the recirculation line quick connect fitting at the tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Remove the fuel tank fill pipe.
- Cap the opening on the fuel tank in order to prevent possible system contamination.
- Remove the cap from the opening on the fuel tank.
- Install the fuel tank fill pipe.
- Connect the recirculation line quick connect fitting at the tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) . NOTE: Refer to «Fastener Notice»(ref-197335-S17275608472005101100000) in Cautions and Notices.
- Tighten the fuel tank fill pipe clamp at the fuel tank. Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
- Position the fuel tank fill pipe ground wire to the frame. Ensure the anti-rotation tab is positioned correctly.
- Install the fuel tank fill pipe ground wire bolt. Tighten: Tighten the bolt to 9 N.m (80 lb in).
- Lower the vehicle.
- Install the fuel tank filler housing.
- Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten: Tighten the bolts to 2.3 N.m (20 lb in).
- Install the fuel tank filler housing to body TORX® screws (1) and retainer (2). Tighten: Tighten the screws to 2.3 N.m (20 lb in).
- Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- If equipped with a rear auxiliary tank, disconnect the fuel and evaporative emission (EVAP) quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Cap the fuel feed and EVAP pipes in order to prevent possible system contamination.
- Loosen the fuel fill pipe clamp (2) at the tank.
- Loosen the vent pipe clamp (1) at the tank.
- Remove the fuel fill pipe and vent pipe from the tank.
- Cap the fuel and vent openings in the tank in order to prevent possible system contamination.
- Remove the caps from the fuel and vent openings in the tank.
- Install the fuel fill pipe and vent pipe to the tank. NOTE: Refer to «Fastener Notice»(ref-197335-S17275608472005101100000) in Cautions and Notices.
- Tighten the vent pipe clamp (1) at the tank.
- Tighten the fuel fill pipe clamp (2) at the tank. Tighten: Tighten the clamps to 2.5 N.m (22 lb in).
- Remove the caps from the fuel feed and EVAP pipes.
- If equipped with a rear auxiliary tank, connect the fuel and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Loosen the fuel fill pipe hose clamp (2) at the tank.
- Loosen the fuel vent pipe hose clamp (1) at the tank.
- Remove the fuel fill and vent hoses from the tank.
- Install the fuel fill and vent hoses to the tank.
- Tighten the fuel vent pipe hose clamp (1) at the tank. NOTE: Refer to «Fastener Notice»(ref-197335-S17275608472005101100000) in Cautions and Notices.
- Tighten the fuel fill pipe hose clamp (2) at the tank. Tighten: Tighten the clamps to 2.5 N.m (22 lb in).
J 45722 Fuel Sender Lock Ring Wrench. See Special Tools .
- Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Front)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect the fuel line from the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect the evaporative emission (EVAP) line from the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Using J 45722 remove the sending unit lock ring. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) . CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container.
- Remove the sending unit and seal. Discard the seal.
- Clean the sending unit sealing surfaces.
| CAUTION | In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. |
| IMPORTANT | The fuel strainer must be in a horizontal position when installing the sending unit is installed in the tank. When installing the sending unit, assure that the fuel strainer does not block full travel of the float arm. |
- Install a NEW sending unit seal.
- Install the sending unit.
- Using J 45722 install the sending unit lock ring. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) .
- Connect the EVAP line to the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Connect the fuel line to the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Front)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
J 44402 Fuel Tank Sending Unit Wrench
- Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Front)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect fuel lines from the sending unit, if required. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Using J 44402 , remove the sending unit lock ring.
- Remove the sending unit and seal. Discard the seal.
- Clean the sending unit sealing surfaces.
| CAUTION | In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. |
| IMPORTANT | The fuel strainer must be in a horizontal position when the sending unit is installed in the tank. When installing the sending unit, assure that the fuel strainer does not block full travel of the float arm. |
- Install a NEW sending unit seal.
- Align the tab, and install the sending unit.
- Using J 44402 , install the sending unit lock ring.
- Connect fuel lines to the sending unit, if required. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Front)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
| IMPORTANT | Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. |
- Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect the fuel feed line (1) at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Disconnect the EVAP canister purge tube line (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Cap the fuel rail and EVAP lines in order to avoid possible system contamination.
- Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197364-S02039416942005101100000) in General Information.
- Remove the fuel pipe bracket nut.
- Remove the fuel pipe bracket from the bellhousing stud.
- Remove the heated oxygen sensor (HO2S) sensor connector from the bracket.
- Remove the fuel line clip from the bracket on the transmission.
- If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case.
- Remove the clip from the bracket on the frame.
- Remove the transfer case harness from the clip bracket.
- Thoroughly wash all contaminants from around the EHCU.
- Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM).
- Disconnect the brake lines from the brake pressure modulator valve (BPMV).
- Remove the bolts (4) attaching the EHCU bracket to the frame (5).
- Remove the EHCU (1).
- If equipped with 4WD, remove the torsion bar bracket. Refer to «Torsion Bar Replacement»(ref-197408-S34474227302005101100000) in Front Suspension.
- Disconnect the fuel and EVAP lines at the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination.
- Remove the fuel and EVAP bundle clip nuts.
- Remove the fuel and EVAP bundle.
- Install the fuel and EVAP bundle.
- Install the fuel and EVAP bundle clip nuts. Tighten: Tighten the nuts to 12 N.m (106 lb in).
- Remove the caps from the fuel and EVAP lines at the fuel tank.
- Connect the fuel and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- If equipped with 4WD, install the torsion bar bracket. Refer to «Torsion Bar Replacement»(ref-197408-S34474227302005101100000) in Front Suspension.
- Install the EHCU (1).
- Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
- Connect the brake lines to the BPMV. Tighten: Tighten the fittings to 25 N.m (18 lb ft).
- Connect the chassis electrical harness connectors to the EBCM.
- Install the transfer case harness to the clip bracket.
- Install the clip to the bracket on the frame.
- If equipped with 4WD, install the fuel line clip to the bracket on the transfer case.
- Install the fuel line clips to the brackets on the transmission.
- Install the HO2S sensor connector to the bracket.
- Install the fuel pipe bracket to the bellhousing stud.
- Install the fuel pipe bracket nut. Tighten: Tighten the nut to 10 N.m (89 lb in).
- Lower the vehicle.
- Remove the caps from the fuel rail and EVAP line.
- Connect the fuel feed line (1) at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Connect the EVAP canister purge tube line (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Install the fuel fill cap.
- Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-197347-S01049574002005101100000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-197347-S39973143602005101100000) in Engine Electrical.
- Use the following procedure in order to inspect for leaks: 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. Inspect for fuel leaks.
| IMPORTANT | Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. |
- Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect the fuel feed line (1) fitting at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Disconnect the EVAP canister purge tube (2) fitting. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Cap the fuel rail and EVAP lines in order to avoid possible system contamination.
- Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197364-S02039416942005101100000) in General Information.
- Remove the fuel pipe bracket nut.
- Remove the fuel pipe bracket from the bellhousing stud.
- Remove the heated oxygen (HO2S) sensor connector from the bracket.
- Remove the fuel line clip from the bracket on the transmission.
- Remove the fuel line clip from the bracket on the transfer case, if equipped with 4 wheel drive (4WD).
- Remove the clip from the bracket on the frame.
- Remove the transfer case harness from the clip bracket.
- Thoroughly wash all contaminants from around the EHCU.
- Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM).
- Disconnect the brake lines from the brake pressure modulator valve (BPMV).
- Remove the bolts (4) attaching the EHCU bracket to the frame (5).
- Remove the EHCU (1).
- Remove the torsion bar bracket, if equipped with 4WD. Refer to «Torsion Bar Replacement»(ref-197408-S34474227302005101100000) in Front Suspension.
- Remove the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect the fuel line at the tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Cap the fuel and EVAP lines in order to avoid possible system contamination.
- Remove the fuel/EVAP bundle clip nuts.
- Remove the fuel/EVAP bundle.
- Install the fuel/EVAP bundle.
- Install the fuel/EVAP bundle clip nuts. Tighten: Tighten the nuts to 12 N.m (106 lb in).
- Remove the caps from the fuel and EVAP lines.
- Connect the fuel line at the tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Install the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Install the torsion bar bracket, if equipped with 4WD. Refer to «Torsion Bar Replacement»(ref-197408-S34474227302005101100000) in Front Suspension.
- Install the EHCU (1).
- Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
- Connect the brake lines to the BPMV. Tighten: Tighten the fittings to 25 N.m (18 lb ft).
- Connect the chassis electrical harness connectors to the EBCM.
- Install the transfer case harness to the clip bracket.
- Install the clip to the bracket on the frame.
- Install the fuel line clip to the bracket on the transfer case, if equipped with 4WD.
- Install the fuel line clip to the bracket on the transmission.
- Install the HO2S sensor connector to the bracket.
- Install the fuel pipe bracket to the bellhousing stud.
- Install the fuel pipe bracket nut. Tighten: Tighten the nut to 10 N.m (89 lb in).
- Lower the vehicle.
- Remove the caps from the fuel rail and EVAP lines.
- Connect the EVAP canister purge tube (2) fitting. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Connect the fuel feed line (1) fitting at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Install the fuel fill cap.
- Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-197347-S01049574002005101100000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-197347-S39973143602005101100000) in Engine Electrical.
- Use the following procedure in order to inspect for leaks: 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. Inspect for fuel leaks.
| IMPORTANT | Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. |
- Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect the fuel feed line (1) at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Disconnect the EVAP canister purge tube line (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Cap the fuel rail in order to avoid possible system contamination.
- Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197364-S02039416942005101100000) in General Information.
- Remove the fuel pipe bracket nut.
- Remove the fuel pipe bracket from the bellhousing stud.
- Remove the fuel line clips from the brackets on the transmission.
- If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case.
- Disconnect the fuel and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination.
- Remove the EVAP line from the clips (2) on the fuel tank.
- Disconnect the quick connect fittings from the EVAP canister.
- Remove the fuel and EVAP bundle nuts.
- Remove the fuel and EVAP bundle.
- Install the fuel and EVAP bundle.
- Install the fuel and EVAP bundle nuts. Tighten: Tighten the nuts to 12 N.m (106 lb in).
- Connect the quick connect fittings to the EVAP canister.
- Install the EVAP line to the clips (2) on the fuel tank.
- Remove the caps from the fuel and EVAP lines.
- Connect the fuel and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- If equipped with 4WD, install the fuel line clip to the bracket on the transfer case.
- Install the fuel line clips to the brackets on the transmission.
- Install the fuel pipe bracket to the bellhousing stud.
- Install the fuel pipe bracket nut. Tighten: Tighten the nut to 10 N.m (89 lb in).
- Lower the vehicle.
- Remove the caps from the fuel rail.
- Connect the EVAP canister purge tube line (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Connect the fuel feed line (1) at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Install the fuel fill cap.
- Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-197347-S01049574002005101100000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-197347-S39973143602005101100000) in Engine Electrical.
- Perform the following procedure in order to inspect for leaks. 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. Inspect for fuel leaks.
| IMPORTANT | Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. |
- Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect the fuel feed and pressure balance lines from the front tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination.
- Disconnect the fuel feed and pressure balance lines from the rear tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination.
- Remove the rear fuel line bundle clip nuts.
- Remove the rear fuel line bundle.
- Install the rear fuel line bundle.
- Install the rear fuel line bundle clip nuts. Tighten: Tighten the nuts to 12 N.m (106 lb in).
- Remove the caps from the fuel and balance lines at the fuel tank.
- Connect the fuel feed and pressure balance lines to the rear tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Remove the caps from the fuel and balance lines at the fuel tank.
- Connect the fuel feed and pressure balance lines to the front tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Install the fuel fill cap.
- Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-197347-S01049574002005101100000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-197347-S39973143602005101100000) in Engine Electrical.
- Perform the following procedure in order to inspect for leaks. 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. Inspect for fuel leaks.
| IMPORTANT | Clean the fuel feed pipe connection and surrounding area prior to disconnecting the fitting in order to avoid possible fuel system contamination. |
- Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Front)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect and remove the fuel feed line (1) from the sending unit and retaining clips.
- Cap the fuel feed and evaporative emission (EVAP) openings in order to prevent possible fuel/EVAP system contamination.
- Remove the caps from the fuel feed/return, and EVAP lines.
- Install and connect the fuel feed (1) line to the sending unit and retaining clips.
- Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Front)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
| IMPORTANT | Clean the fuel feed pipe connection and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel system contamination. |
- Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Front)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect and remove the fuel feed (1) line from the sending unit and retaining clips.
- Cap the fuel feed/return, and evaporative emission (EVAP) lines in order to prevent possible fuel/EVAP system contamination.
- Remove the caps from the fuel feed/return, and EVAP lines.
- Install and connect the fuel feed (1) line to the sending unit and retaining clips.
- Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Front)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
Fuel Tank Cleaning
| IMPORTANT | Only use oil free compressed air to blow out the fuel pipes. Inspect the fuel tank internally and clean the fuel tank if you find a plugged fuel filter. |
- Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-197347-S01049574002005101100000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-197347-S39973143602005101100000) in Engine Electrical.
- Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Drain the fuel tank. Refer to «Fuel Tank Draining Procedure (4.8L, 5.3L, and 6.0L Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Draining Procedure (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__fuel-tank-draining-procedure-53l) .
- Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Front)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Remove the fuel sender assembly. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Inspect the fuel pump strainer. Replace a contaminated strainer and inspect the fuel pump.
- Inspect the fuel pump inlet for dirt and debris. Replace the fuel pump if you find dirt or debris in the fuel pump inlet.
- Flush the fuel tank with hot water.
- Pour the water out of the fuel sender assembly opening. Rock the tank to be sure that removal of the water from the tank is complete.
- Remove the fuel rail assembly. Refer to «Fuel Rail Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Rail Assembly Replacement (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Drain the fuel from the fuel rail. It will be necessary to remove the fuel injectors from the fuel rail to properly clear all debris from the fuel rail and fuel injectors. Use light shop air to remove any debris from the fuel rail and injectors.
- Replace the fuel injector O-rings.
- Use light shop air in the opposite direction of the fuel flow in order to remove any debris from the fuel lines. Catch any fuel from the fuel lines with an approved gasoline container.
- Install the injectors to the fuel rail.
- Install the fuel rail assembly onto the engine. Refer to «Fuel Rail Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Rail Assembly Replacement (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- If equipped with a serviceable fuel filter, replace the fuel filter.
- Install the fuel sender assembly. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Front)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Refill the fuel tank.
- Install the fuel filler cap.
- Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-197347-S01049574002005101100000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-197347-S39973143602005101100000) in Engine Electrical.
- Purge the fuel sender assembly. Disconnect the fuel feed line from the fuel filter. Connect a length of hose to the fuel feed pipe. Insert the other end of the hose into an empty 3.8 liter (1 gallon) approved gasoline container. Add 23 liters (6 gallons) of clean fuel into the fuel tank. Turn on the fuel pump using the scan tool until 2 liters (1/2 gallon) of fuel flows into the fuel container.
- Inspect for leaks. Turn the ignition switch ON for 2 seconds. Turn the ignition switch OFF for 10 seconds. Turn the ignition switch ON. Inspect for fuel leaks.
| IMPORTANT | An 8-digit identification number (1) is located on the fuel rail. Refer to this identification number when servicing or when part replacement is required. |
- Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Remove the wire harness bracket nut (2).
- Disconnect the evaporative emission (EVAP) purge solenoid electrical connector (1).
- Disconnect the generator electrical connector (3).
- Disconnect the following electrical connectors: Manifold absolute pressure (MAP) sensor (1) Knock sensor (2)
- Remove the knock sensor harness connector from the intake manifold.
- Disconnect the electronic throttle control (ETC) electrical connector (2), preform the following: Disengage the gray retainer. Push down the black clip. Disconnect the connector.
- Remove the connector position assurance (CPA) retainer (5).
- Disconnect the following electrical connectors from the right side of the engine: Main coil (4) Fuel injectors (3)
- Remove the harness clips from the fuel rail (1).
- Remove the CPA retainer from the left side of the engine.
- Disconnect the following electrical connectors from the left side of the engine: Main coil (2) Fuel injectors
- Remove the harness clips from the fuel rail (1).
- Reposition the engine wire harness aside.
- Perform the following steps in order to disconnect the fuel injector electrical connectors. Mark the connectors to their corresponding injectors to ensure correct reassembly. Pull the connector position assurance (CPA) retainer (2) on the connector up 1 click. Push the tab (1) on the connector in. Disconnect the fuel injector electrical connector. Repeat the steps for each injector electrical connector.
- Remove the positive crankcase ventilation (PCV) hose.
- Disconnect the fuel feed pipe (1) from the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Remove the fuel rail bolts.
- Remove the fuel rail.
- Remove the fuel injector lower O-ring seal (4) from each injector, if necessary.
- Discard the O-ring seal.
- Lubricate NEW fuel injector lower O-ring seals (4) with clean engine oil.
- Install the NEW O-ring seals (4) onto each injector, if necessary.
- Install the fuel rail.
- Apply a 5 mm (0.2 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the fuel rail bolts.
- Install the fuel rail bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
- Connect the fuel feed pipe (1) to the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Install the PCV hose.
- Perform the following steps in order to connect the fuel injector electrical connectors. Install the connectors to their corresponding injectors to ensure correct reassembly. Connect the fuel injector electrical connector. Push the CPA retainer (2) on the connector in 1 click. Repeat the steps for each injector electrical connector.
- Position the engine wire harness.
- Connect the following electrical connectors to the left side of the engine: Main coil (2) Fuel injectors
- Install the harness clips to the fuel rail (1).
- Install the CPA retainer.
- Connect the following electrical connectors to the right side of the engine: Main coil (4) Fuel injectors (3)
- Install the CPA retainer (5).
- Install the harness clips to the fuel rail (1).
- Connect the ETC electrical connector (2), preform the following: Connect the connector. Engage the gray retainer.
- Connect the following electrical connectors: MAP sensor (1) Knock sensor (2)
- Install the knock sensor harness connector to the intake manifold.
- Connect the EVAP purge solenoid electrical connector (1).
- Connect the generator electrical connector (3).
- Install the wire harness bracket nut (2). Tighten: Tighten the nut to 5 N.m (44 lb in).
- Tighten the fuel fill cap.
- Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-197347-S01049574002005101100000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-197347-S39973143602005101100000) in Engine Electrical.
- Use the following procedure in order to inspect for leaks: 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. Inspect for fuel leaks.
- Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Remove the wire harness bracket nut (2).
- Disconnect the evaporative emission (EVAP) purge solenoid electrical connector (1).
- Disconnect the generator electrical connector (3).
- Disconnect the following electrical connectors: Manifold absolute pressure (MAP) sensor (1) Knock sensor (2)
- Remove the knock sensor harness connector from the intake manifold.
- Remove the connector position assurance (CPA) retainer.
- Disconnect the following electrical connectors from both sides of the engine: Main coil (2) Fuel injectors
- Remove the harness clips from the fuel rail (1).
- Reposition the upper engine wire harness aside.
- Perform the following steps in order to disconnect the fuel injector electrical connectors: Mark the connectors to their corresponding injectors to ensure correct reassembly. Pull the connector position assurance (CPA) retainer (2) on the connector up 1 click. Push the tab (1) on the connector in. Disconnect the fuel injector connector electrical connector. Repeat the steps for each injector connector.
- Remove the positive crankcase ventilation (PCV) hose.
- Disconnect the fuel feed and return pipes (1, 2) from the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Disconnect the fuel pressure regulator vacuum line.
- Remove the fuel rail bolts.
- Remove the fuel rail.
- Remove the fuel injector lower O-ring seal (4) from each fuel injector, if necessary.
- Discard the O-ring seal.
- Lubricate the NEW fuel injector lower O-ring seals (4) with clean engine oil.
- Install the NEW O-ring seals (4) onto each injector, if necessary.
- Install the fuel rail.
- Apply a 5 mm (0.020 in) band of threadlock, GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the fuel rail bolts.
- Install the fuel rail bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
- Connect the fuel pressure regulator vacuum line.
- Connect the fuel feed and return pipes (1, 2) to the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Install the PCV hose.
- Perform the following steps in order to connect the fuel injector electrical connectors. Install the connectors to their corresponding injectors to ensure correct reassembly. Connect the fuel injector electrical connector. Push the CPA retainer (2) in the connector in 1 click. Repeat the steps for each injector electrical connector.
- Position the engine wire harness.
- Connect the following electrical connectors to both sides of the engine: Main coil (2) Fuel injectors
- Install the harness clips to the fuel rail (1).
- Install the CPA retainers.
- Connect the following electrical connectors: MAP sensor (1) Knock sensor (2)
- Install the knock sensor harness connector to the intake manifold.
- Connect the EVAP purge solenoid electrical connector (1).
- Connect the generator electrical connector (3).
- Install the wire harness bracket nut (2). Tighten: Tighten the nut to 5 N.m (44 lb in).
- Tighten the fuel fill cap.
- Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-197347-S01049574002005101100000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-197347-S39973143602005101100000) in Engine Electrical.
- Use the following procedure in order to inspect for leaks: 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. Inspect for fuel leaks.
Note. Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method.
| IMPORTANT | The engine oil may be contaminated with fuel if the fuel injectors are leaking. |
- Remove the fuel rail. Refer to «Fuel Rail Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Rail Assembly Replacement (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Remove and discard the fuel injector retainer clip (19).
- Remove the fuel injector (17).
- Remove and discard the fuel injector retainer clip (1).
- Remove and discard the fuel injector O-ring seals (2, 4).
Scheme 94
| IMPORTANT | When ordering new fuel injectors, you must order the correct injector for the application being serviced. |
The fuel injector (1) is stamped with a identification part number (2). A four-digit build date code (3) indicates the month (4), day (5), year (6), and shift (7) that built the injector.
- Lubricate the NEW injector O-ring seals (2, 4) with clean engine oil.
- Install the NEW injector O-ring seals onto the fuel injector.
- Install a NEW retainer clip (1) onto the fuel injector.
- Push the fuel injector (17) into the fuel rail injector socket with the electrical connector facing outward. The retainer clip (19) locks on to a flange on the fuel rail injector socket.
- Install the fuel rail. Refer to «Fuel Rail Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Rail Assembly Replacement (5.3L (L59) Engine)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
Fuel Injector Cleaning Procedure
Tools Required
- J 37287 Fuel Line Shut-Off Adapters
- J 35800-A Fuel Injector Cleaner. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) .
- J 42873-1 3/8 Fuel Line Shut-Off Valve. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) .
- J 42873-2 5/16 Return Pipe Shut-Off Valve. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) .
- J 42964-1 3/8 Fuel Pipe Shut-Off Valve. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) .
- J 42964-2 5/16 Fuel Pipe Shut-Off Valve. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) .
Note. GM Top-Engine Cleaner is the only injector cleaning agent recommended. Do not use other cleaning agents, as they may contain methanol which can damage fuel system components. Under NO circumstances should the top engine cleaner be added to the vehicles fuel tank, as it may damage the fuel pump and other system components. Do not exceed a 10 percent cleaning solution concentration. Higher concentrations may damage fuel system components. Testing has demonstrated that exceeding the 10 percent cleaning solution concentration does not improve the effectiveness of this procedure.
| IMPORTANT | Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned. These vehicles should have the injectors replaced. |
| IMPORTANT | During this procedure you will need a total of 960 ml (32.4 oz) of cleaning solution. That is 2 tanks of solution for the J 35800-A . See Special Tools . Other brands of tools may have a different capacity and would therefore require more or less tanks to complete the procedure. You must use all 960 ml (32.4 oz) of solution to ensure complete injector cleaning. |
- Obtain J 35800-A (2). See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) .
- For US dealers, empty 2 pre-measured GM Top-Engine Cleaner containers, 24 ml (0.812 oz) each, GM P/N 12346535, into the J 35800-A . See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) .
- For Canadian dealers, measure and dispense 48 ml (1.62 oz) of Top-Engine Cleaner, Canadian P/N 992872, into the J 35800-A . See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) .
- If you are using any other brand of tank you will need a total of 96 ml (3.24 oz) of Top-Engine Cleaner mixed with 864 ml (29.16 oz) of regular unleaded gasoline.
- Fill the injector cleaning tank with regular unleaded gasoline. Be sure to follow all additional instructions provided with the tool.
- Electrically disable the vehicle fuel pump by removing the fuel pump relay and disconnecting the oil pressure switch connector, if equipped.
- Disconnect the fuel feed and return line, if equipped, at the fuel rail. Plug the fuel feed and return line, if equipped, coming off the fuel rail with J 37287 , or J 42964-1 , and. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) . J 42964-2 or. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) . J 42873-1 , and. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) . J 42873-2 as appropriate for the fuel system. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) .
- Connect the J 35800-A to the vehicle fuel rail. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) .
- Pressurize the J 35800-A to 510 kPa (75 psi). See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) .
- Start and idle the engine until it stalls due to lack of fuel. This should take approximately 15-20 minutes.
- Disconnect J 35800-A from the fuel rail. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) .
- Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped.
- Remove J 37287 or J 42964-1 , and. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) . J 42964-2 or. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) . J 42873-1 , and. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) . J 42873-2 and reconnect the vehicle fuel feed and return lines. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__special-tools) .
- Start and idle the vehicle for an additional 2 minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines.
- Repeat steps 1-5 of the Injector Balance Test, and record the fuel pressure drop from each injector.
- Subtract the lowest fuel pressure drop from the highest fuel pressure drop. If the value is 15 kPa (2 psi) or less, no additional action is required. If the value is greater than 15 kPa (2 psi), replace the injector with the lowest fuel pressure drop.
- Add one ounce of Port Fuel Injector Cleaner, GM P/N 12345104 (Canadian P/N 10953467), to the vehicle fuel tank for each gallon of gasoline estimated to be in the fuel tank. Instruct the customer to add the reminder of the bottle of Port Fuel Injector Cleaner to the vehicle fuel tank at the next fill-up.
- Advise the customer to change brands of fuel and to add GM Port Fuel Injector Cleaner every 5 000 km (3,000 mi). GM Port Fuel Injector Cleaner contains the same additives that the fuel companies are removing from the fuel to reduce costs. Regular use of GM Port Fuel Injector Cleaner should keep the customer from having to repeat the injector cleaning procedure.
- Road test the vehicle to verify that the customer concern has been corrected.
- Remove the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L (RPO LQ4))»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/mechanical/#engine-mechanical-48l-53l-60l-repair-instructions-1-of-3) or «Engine Sight Shield Replacement (6.0L (RPO LQ9))»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/mechanical/#engine-mechanical-48l-53l-60l-repair-instructions-1-of-3) in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
- Remove the evaporative emission (EVAP) line from the canister purge solenoid, perform the following: Push the large size white retainer portion in. Push down, while pulling up slightly in order the disengage the tube.
- Disconnect the EVAP canister purge solenoid electrical connector (1).
- Remove the EVAP canister purge solenoid bolt (2).
- Remove the EVAP canister purge solenoid (3) and insulator (1).
- Install the insulator (1) onto the EVAP canister purge solenoid (3).
- Install the EVAP canister purge solenoid (3). NOTE: Refer to «Fastener Notice»(ref-197335-S17275608472005101100000) in Cautions and Notices.
- Install the EVAP canister purge solenoid bolt (2). Tighten: Tighten the bolt to 10.5 N.m (93 lb in).
- Connect the EVAP canister purge solenoid electrical connector (1).
- Install the EVAP line to the canister purge solenoid (1).
- Install the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L (RPO LQ4))»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/mechanical/#engine-mechanical-48l-53l-60l-repair-instructions-1-of-3) or «Engine Sight Shield Replacement (6.0L (RPO LQ9))»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/mechanical/#engine-mechanical-48l-53l-60l-repair-instructions-1-of-3) in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
| IMPORTANT | Clean the evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. |
- Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197364-S02039416942005101100000) in General Information.
- Remove the harness clip from the canister vent solenoid (CVS) line.
- Disconnect the CVS electrical connector.
- If the vehicle is equipped with a 6 ft box, disconnect the EVAP CVS line from the canister.
- Remove the CVS clip from the frame crossmember.
- Push in the retainer and remove the CVS from the fuel tank clip.
- If the vehicle is equipped with a 8 ft box, disconnect the EVAP CVS line from the canister.
- Remove the CVS clip from the frame crossmember.
- Push in the retainer and remove the CVS from the fuel tank clip.
- If the vehicle is equipped with a 8 ft box, install the CVS to the fuel tank until the clip engages.
- Install the CVS clip to the frame crossmember.
- Connect the EVAP CVS line to the canister.
- If the vehicle is equipped with a 6 ft box, install the CVS to the fuel tank until the clip engages.
- Install the CVS clip to the frame crossmember.
- Connect the EVAP CVS line to the canister.
- Connect the CVS electrical connector.
- Install the harness clip to the canister vent solenoid (CVS) line.
- Lower the vehicle.
- Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197364-S02039416942005101100000) in General Information.
- Disconnect the canister vent solenoid (CVS) electrical connector (1).
- Remove the CVS bracket bolt.
- Disconnect the CVS line from the evaporative emission (EVAP) canister. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Remove the CVS from the vehicle.
- If necessary, remove the CVS from the CVS bracket.
- If necessary, install the CVS to the CVS bracket.
- Install the CVS to the vehicle. Ensure the locator tab is inserted into the frame hole.
- Connect the CVS line to the canister. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) . NOTE: Refer to «Fastener Notice»(ref-197335-S17275608472005101100000) in Cautions and Notices.
- Install the CVS bracket bolt. Tighten: Tighten the bolt to 12 N.m (106 lb in).
- Connect the CVS electrical connector (1).
- Lower the vehicle.
| IMPORTANT | Clean all evaporative emission (EVAP) connections and surrounding areas before disconnecting the line in order to avoid possible EVAP system contamination. |
- Disconnect the EVAP canister vent solenoid (CVS) electrical connector (1).
- Remove the EVAP CVS valve bracket bolt (1).
- Remove the EVAP CVS line from the clips on the fuel tank.
- Remove the CVS valve and line.
- Remove the EVAP CVS valve line from the CVS, if necessary.
- Install the EVAP CVS valve line to the CVS, if necessary.
- Install the CVS valve and line. NOTE: Refer to «Fastener Notice»(ref-197335-S17275608472005101100000) in Cautions and Notices.
- Install the EVAP CVS valve bracket bolt (1). Tighten: Tighten the bolt to 12 N.m (106 lb in).
- Install the EVAP CVS line to the clips on the fuel tank.
- Connect the EVAP CVS electrical connector (1).
| IMPORTANT | Clean the evaporative emission (EVAP) pipe connections and surrounding area prior to disconnecting the fittings in order to avoid possible fuel system contamination. |
- Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Front)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect and remove the EVAP purge line (2) from the sending unit and retaining clips. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect and remove the EVAP fuel level vent valve (FLVV) line (3) from the sending unit and retaining clips. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Cap the fuel feed and EVAP openings in order to prevent possible fuel/EVAP system contamination.
- Remove the caps from the fuel feed and EVAP lines.
- Install and connect the EVAP FLVV line (3) line to the sending unit and retaining clips. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Install and connect the EVAP purge line (2) to the sending unit and retaining clips. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Front)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
| IMPORTANT | Clean the evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. |
- Remove the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L (RPO LQ4))»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/mechanical/#engine-mechanical-48l-53l-60l-repair-instructions-1-of-3) or «Engine Sight Shield Replacement (6.0L (RPO LQ9))»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/mechanical/#engine-mechanical-48l-53l-60l-repair-instructions-1-of-3) in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
- Disconnect the EVAP tube from the EVAP canister purge solenoid (1). Push the large side white retainer portion in. Push down, while pulling up slightly in order to disengage the tube.
- Disconnect the EVAP tube from the chassis EVAP pipe (2). Push the large side white retainer portion in. Push down, while pulling up slightly in order to disengage the tube.
- Remove the EVAP tube.
- Cap the EVAP canister purge solenoid and EVAP chassis pipe in order to prevent possible EVAP system contamination.
- Remove the caps from the EVAP canister purge solenoid and EVAP chassis pipe.
- Install the EVAP tube.
- Connect the EVAP tube to the EVAP chassis pipe (2).
- Connect the EVAP tube to the EVAP purge solenoid (1).
- Install the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L (RPO LQ4))»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/mechanical/#engine-mechanical-48l-53l-60l-repair-instructions-1-of-3) or «Engine Sight Shield Replacement (6.0L (RPO LQ9))»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/mechanical/#engine-mechanical-48l-53l-60l-repair-instructions-1-of-3) in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
| IMPORTANT | Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. |
- Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect the fuel feed line (1) at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Disconnect the EVAP canister purge tube line (2).
- Cap the fuel rail in order to avoid possible system contamination.
- Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197364-S02039416942005101100000) in General Information.
- Remove the fuel pipe bracket nut.
- Remove the fuel pipe bracket from the bellhousing stud.
- Remove the fuel line clips from the brackets on the transmission.
- If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case.
- Disconnect the fuel and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination.
- Remove the fuel and EVAP bundle nuts.
- Remove the fuel and EVAP bundle.
- Install the fuel and EVAP bundle.
- Install the fuel and EVAP bundle nuts. Tighten: Tighten the nuts to 12 N.m (106 lb in).
- Remove the caps from the fuel and EVAP lines at the fuel tank.
- Connect the fuel and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- If equipped with 4WD, install the fuel line clip to the bracket on the transfer case.
- Install the fuel line clip(s) to the bracket(s) on the transmission.
- Install the fuel pipe bracket to the bellhousing stud.
- Install the fuel pipe bracket nut. Tighten: Tighten the nut to 10 N.m (89 lb in).
- Lower the vehicle.
- Remove the cap from the fuel rail.
- Connect the fuel feed line (1) at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Connect the EVAP canister purge tube line (2).
- Install the fuel fill cap.
- Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-197347-S01049574002005101100000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-197347-S39973143602005101100000) in Engine Electrical.
- Use the following procedure in order to inspect for leaks: 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. Inspect for fuel leaks.
| IMPORTANT | Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. |
- Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect the fuel feed line (1) fitting at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Disconnect the EVAP canister purge tube (2) fitting. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Cap the fuel rail and EVAP lines in order to avoid possible system contamination.
- Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197364-S02039416942005101100000) in General Information.
- Remove the fuel pipe bracket nut.
- Remove the fuel pipe bracket from the bellhousing stud.
- Remove the heated oxygen (HO2S) sensor connector from the bracket.
- Remove the fuel line clips from the brackets on the transmission.
- Remove the fuel line clip from the bracket on the transfer case, if equipped with 4 wheel drive (4WD).
- Remove the clip from the bracket on the frame.
- Remove the transfer case harness from the clip bracket.
- Thoroughly wash all contaminants from around the EHCU.
- Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM).
- Disconnect the brake lines from the brake pressure modulator valve (BPMV).
- Remove the bolts (4) attaching the EHCU bracket to the frame (5).
- Remove the EHCU (1).
- Remove the torsion bar bracket, if equipped with 4WD. Refer to «Torsion Bar Replacement»(ref-197408-S34474227302005101100000) in Front Suspension.
- Remove the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect the fuel line at the tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Cap the fuel and EVAP lines in order to avoid possible system contamination.
- Remove the fuel/EVAP bundle clip nuts.
- Remove the fuel/EVAP bundle.
- Install the fuel/EVAP bundle.
- Install the fuel/EVAP bundle clip nuts. Tighten: Tighten the nuts to 12 N.m (106 lb in).
- Remove the caps from the fuel and EVAP lines.
- Connect the fuel line at the tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Install the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Install the torsion bar bracket, if equipped with 4WD. Refer to «Torsion Bar Replacement»(ref-197408-S34474227302005101100000) in Front Suspension.
- Install the EHCU (1).
- Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
- Connect the brake lines to the BPMV. Tighten: Tighten the fittings to 25 N.m (18 lb ft).
- Connect the chassis electrical harness connectors to the EBCM.
- Install the transfer case harness to the clip bracket.
- Install the clip to the bracket on the frame.
- Install the fuel line clip to the bracket on the transfer case, if equipped with 4WD.
- Install the fuel line clips to the brackets on the transmission.
- Install the HO2S sensor connector to the bracket.
- Install the fuel pipe bracket to the bellhousing stud.
- Install the fuel pipe bracket nut. Tighten: Tighten the nut to 10 N.m (89 lb in).
- Lower the vehicle.
- Remove the caps from the fuel rail and EVAP lines.
- Connect the EVAP canister purge tube (2) fitting. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Connect the fuel feed line (1) fitting at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Install the fuel fill cap.
- Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-197347-S01049574002005101100000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-197347-S39973143602005101100000) in Engine Electrical.
- Use the following procedure in order to inspect for leaks: 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. Inspect for fuel leaks.
| IMPORTANT | Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. |
- Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect the fuel feed and pressure balance lines from the front tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination.
- Disconnect the fuel feed and pressure balance lines from the rear tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination.
- Remove the rear fuel line bundle clip nuts.
- Remove the rear fuel line bundle.
- Install the rear fuel line bundle.
- Install the rear fuel line bundle clip nuts.
- Remove the caps from the fuel and balance lines at the fuel tank.
- Connect the fuel feed and pressure balance lines from the rear tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Remove the caps from the fuel and balance lines at the fuel tank.
- Connect the fuel feed and pressure balance lines from the front tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__quick-connect-fittings-service-metal-collar) .
- Install the fuel fill cap.
- Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-197347-S01049574002005101100000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-197347-S39973143602005101100000) in Engine Electrical.
- Perform the following procedure in order to inspect for leaks. 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. Inspect for fuel leaks.
| IMPORTANT | Clean all the evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel/EVAP system contamination. |
- Remove the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Remove the EVAP canister line (1). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Remove the EVAP canister purge line (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Cap the fuel and EVAP lines in order to prevent possible fuel/EVAP system contamination.
- Remove the caps from the fuel and EVAP lines.
- Install the EVAP canister purge line (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Install the EVAP canister line (1). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Install the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
| IMPORTANT | Clean all evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. |
- Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197364-S02039416942005101100000) in General Information.
- Disconnect the EVAP canister vent solenoid (CVS) line from the EVAP canister.
- Disconnect the fuel tank EVAP line from the canister.
- Disconnect the canister EVAP line from the fuel bundle line.
- Remove the EVAP canister nut.
- Remove the EVAP canister with shield from the bracket.
- If necessary, remove the EVAP canister from the shield, perform the following: Lift up the retaining clip on the bottom of the canister. Remove the canister from the shield.
- If necessary, disconnect the EVAP lines from the canister.
- If necessary, connect the EVAP lines to the canister.
- If necessary, install the EVAP canister to the shield, perform the following: Install the canister to the shield. Ensure the retaining clip engages on the bottom of the canister.
- Install the EVAP canister with shield to the bracket. NOTE: Refer to «Fastener Notice»(ref-197335-S17275608472005101100000) in Cautions and Notices.
- Install the EVAP canister nut. Tighten: Tighten the nut to 25 N.m (18 lb ft).
- Connect the canister EVAP line to the fuel bundle line.
- Connect the fuel tank EVAP line to the canister.
- Connect the EVAP CVS line to the canister.
- Lower the vehicle.
| IMPORTANT | Clean all evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. |
- Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197364-S02039416942005101100000) in General Information.
- Disconnect the canister vent solenoid (CVS) line from the EVAP canister. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect the fuel/EVAP bundle line from the EVAP canister. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect the fuel tank line from the EVAP canister. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Remove the EVAP canister bracket bolts.
- Remove the EVAP canister from the bracket, if necessary.
- Install the EVAP canister to the bracket, if necessary.
- Install the EVAP canister bracket bolts. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
- Connect the fuel tank line to the EVAP canister. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Connect the fuel/EVAP bundle line to the EVAP canister. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Connect the CVS line to the EVAP canister. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Lower the vehicle.
| IMPORTANT | Clean all evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. |
- Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197364-S02039416942005101100000) in General Information.
- Disconnect the EVAP canister vent solenoid (CVS) line from the canister.
- Disconnect the fuel tank EVAP line from the canister.
- Disconnect the canister EVAP line from the fuel bundle line.
- Remove the EVAP canister nuts.
- Remove the EVAP canister.
- Install the EVAP canister.
- Install the EVAP canister nuts. Tighten: Tighten the nuts to 25 N.m (18 lb ft).
- Connect the canister EVAP line to the fuel bundle line.
- Connect the fuel tank EVAP line to the canister.
- Connect the EVAP CVS line to the canister.
- Lower the vehicle.
J 41413-200 EVAP Pressure/Purge Diagnostic Station
Inspection Procedure
| IMPORTANT | Do not perform this procedure unless instructed by an EVAP diagnostic. |
- Turn OFF the ignition.
- Remove the EVAP canister purge valve. Refer to «Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Lightly tap the EVAP canister purge valve on a clean hard surface.
- Inspect for carbon particles exiting either of the vacuum ports. If no carbon particles are found reinstall the EVAP canister purge valve and continue with the EVAP cleaning procedure. Refer to «Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) . If carbon particles are found during the inspection procedure, replace the EVAP canister purge valve and continue with the EVAP cleaning procedure. Refer to «Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) . If you were instructed to replace the EVAP canister purge valve, and no carbon particles are found, return to the EVAP diagnostic procedure. Do not perform the EVAP cleaning procedure.
EVAP Cleaning Procedure
- Remove the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Turn OFF the main valve on J 41413-200 .
- Disconnect the hose from the diagnostic station pressure regulator.
- Using a section of vacuum hose, connect one end to the diagnostic station pressure regulator.
- Connect the other end of the vacuum hose to the canister side of the purge pipe.
- Turn ON the main nitrogen cylinder valve and continue to discharge nitrogen for 15 seconds.
- If the nitrogen does not dislodge the carbon particles, replace the purge pipe.
- Return the EVAP pressure/purge diagnostic station to the stations original condition.
- Install a new EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Connect all previously disconnected EVAP pipe connectors.
- Lower the vehicle.
- Continue with the published service manual diagnostic DTC procedure.
- If equipped with regular production option (RPO) HP2, disconnect the energy storage box (ESB). Refer to «Energy Storage Box (ESB) Service Disconnect/Connect (5.3L Engine w/RPO HP2)»(ref-197347-S06035849192005101100000) in Engine Electrical.
- Remove the spark plug wire from the ignition coil.
- Disconnect the ignition coil electrical connector.
- If equipped with regular production option (RPO) HP2, remove the auxiliary heater water pump bracket bolts.
- Remove the auxiliary heater water pump from the studs, and reposition out of the way.
- If equipped with RPO HP2, remove the starter/generator control module (SGCM) cover bolts, and cover.
- Remove the 3-phase cable nuts to the SGCM.
- Remove the 3-phase cable from the SGCM.
- If equipped with RPO HP2, remove the 3-phase cable bracket nuts (2).
- Remove the 3-phase cable bracket (1) from the studs, and reposition the cable and bracket out of the way.
- Remove the ignition coil bolts.
- Remove the ignition coil.
- Install the ignition coil.
- Install the ignition coil bolts. Tighten: Tighten the bolts to 8 N.m (71 lb in).
- If equipped with RPO HP2, position the cable (w/bracket) and install the 3-phase cable bracket to the studs.
- Install the 3-phase cable bracket nuts (2). Tighten: Tighten the nuts to 15 N.m (11 lb ft).
- If equipped with RPO HP2, install the 3-phase cable to the SGCM.
- Install the 3-phase cable nuts to the SGCM. Tighten: Tighten the nuts to 9 N.m (80 lb in).
- Install the SGCM cover and bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
- If equipped with RPO HP2, position the auxiliary heater water pump and install it onto the studs.
- Install the auxiliary heater water pump bracket bolts. Tighten: Tighten the bolts to 15 N.m (11 lb ft).
- Connect the ignition coil electrical connector.
- Install the spark plug wire to the ignition coil.
- If equipped with RPO HP2, connect the ESB. Refer to «Energy Storage Box (ESB) Service Disconnect/Connect (5.3L Engine w/RPO HP2)»(ref-197347-S06035849192005101100000) in Engine Electrical.
Spark Plug Wire Inspection
Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions
- Correct routing of the spark plug wires-Incorrect routing may cause cross-firing.
- Any signs of cracks or splits in the wires.
- Inspect each boot for the following conditions: Tearing Piercing Arcing Carbon tracking Corroded terminal
If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire.
- Remove the spark plug wire from the spark plug. Twist the spark plug wire boot a 1/2 turn. Pull only on the boot in order to remove the wire from the spark plug.
- Remove the spark plug wire from the ignition coil. Twist the spark plug wire boot a 1/2 turn. Pull only on the boot in order to remove the wire from the ignition coil.
- There are 2 different manufacturers for the spark plug wire, ignition coils and coil brackets. They are as follows
- The Melco® spark plug wire (1) will have a blue foil mark on it, and the wire is 145 mm (5.70 in) in length from cable seal to cable seal.
- The Delphi® spark plug wire (2) will have a white foil mark on it, and the wire is 110 mm (4.30 in) in length cable seal to cable seal.
- The Melco® (1) ignition coil is a square design.
- The Delphi® (2) ignition coil is a round design.
- The Melco® ignition coil bracket (1) is a square design.
- The Delphi® ignition coil bracket (2) is a round design.
- Install the spark plug wire to the ignition coil.
- Install the spark plug wire to the spark plug.
- Inspect the spark plug wire for proper installation: Push sideways on each boot in order to inspect the seating. Reinstall any loose boot.
Spark Plug Inspection
- Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to «Ignition System Specifications»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__ignition-system-specifications) for the correct spark plug.
- Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling - Colder plug Pre-ignition causing spark plug and/or engine damage - Hotter plug
- Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move.
- Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground.
- Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4).
- Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3). Refer to «Ignition System Specifications»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__ignition-system-specifications) . An excessively wide electrode gap can prevent correct spark plug operation. Inspect for the correct spark plug torque. Refer to «Ignition System Specifications»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__ignition-system-specifications) . Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). Inspect for a broken or worn side electrode (3). Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. A loose center electrode (4) reduces the spark intensity. Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. Inspect for excessive fouling.
- Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation.
Visual Inspection
- Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives.
- Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors Excessive fuel pressure Restricted air filter element Incorrect combustion Reduced ignition system voltage output Weak ignition coils Worn ignition wires Incorrect spark plug gap Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off.
- Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode.
- Remove the spark plug wire. Refer to «Spark Plug Wire Replacement»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Loosen the spark plug 1 or 2 turns.
- Brush or using compressed air, blow away any dirt from around the spark plug.
- Remove the spark plug. If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number.
- Correctly position the spark plug washer.
- Inspect the spark plug gap. Adjust the gap as needed. Specification: Spark plug gap: 1.016 mm (0.040 in)
- Hand start the spark plug in the corresponding cylinder. NOTE: Refer to «Fastener Notice»(ref-197335-S17275608472005101100000) in Cautions and Notices.
- Tighten the spark plug. Tighten: Tighten the plug to 15 N.m (11 lb ft) for used heads. Tighten the plug to 20 N.m (15 lb ft) for NEW heads.
- Install the spark plug wire. Refer to «Spark Plug Wire Replacement»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
| IMPORTANT | Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. |
- Remove the starter. Refer to «Starter Motor Replacement (4.3L Engine)»(ref-197347-S26665921402005101100000) or «Starter Motor Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-197347-S19364111122005101100000) or «Starter Motor Replacement (6.6L (LLY) Engine)»(ref-197347-S05014819162005101100000) or «Starter Motor Replacement (8.1L Engine)»(ref-197347-S22221360782005101100000) in Engine Electrical.
- Disconnect the crankshaft position (CKP) sensor electrical connector.
- Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine.
- Remove the CKP sensor bolt.
- Remove the CKP sensor.
- Install the CKP sensor.
- Install the CKP sensor bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
- Connect the CKP sensor electrical connector.
- Install the starter. Refer to «Starter Motor Replacement (4.3L Engine)»(ref-197347-S26665921402005101100000) or «Starter Motor Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-197347-S19364111122005101100000) or «Starter Motor Replacement (6.6L (LLY) Engine)»(ref-197347-S05014819162005101100000) or «Starter Motor Replacement (8.1L Engine)»(ref-197347-S22221360782005101100000) in Engine Electrical.
- Perform the CKP system variation learn procedure. Refer to «CKP System Variation Learn Procedure»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction__ckp-system-variation-learn-procedure) .
| IMPORTANT | Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. |
- Remove the CMP sensor bolt.
- Remove the CMP sensor.
- Install the CMP sensor.
- Install the CMP sensor bolt. Tighten: Tighten the bolt to 29 N.m (21 lb ft).
- Remove the intake manifold. Refer to «Intake Manifold Replacement»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/mechanical/#engine-mechanical-48l-53l-60l-repair-instructions-1-of-3) in Engine Mechanical-4.8L, 5.3L, and 6.0L.
- Gently pry up the rubber covers.
- Disconnect the knock sensor electrical connectors.
- Remove the knock sensors.
- Install the knock sensors. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
- Connect the knock sensor electrical connectors.
- Push down on the rubber covers.
- Install the intake manifold. Refer to «Intake Manifold Replacement»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/mechanical/#engine-mechanical-48l-53l-60l-repair-instructions-1-of-3) in Engine Mechanical-4.8L, 5.3L, and 6.0L.
- Remove the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (4).
- Loosen the air cleaner housing top screws.
- Remove the air cleaner housing cover.
- Remove the air filter element.
- Install a NEW air filter element.
- Install the air cleaner housing cover.
- Tighten the air cleaner housing top screws until snug.
- Connect the MAF/IAT sensor electrical connector (4).
- Install the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Remove the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (4).
- Pull up on the air cleaner assembly (1) in order to release the retainers from the air cleaner adaptor (2).
- If necessary, loosen the MAF/IAT clamp.
- If necessary, remove the MAF/IAT sensor.
- If necessary, install the MAF/IAT sensor.
- If necessary, tighten the MAF/IAT clamp. Tighten: Tighten the clamp to 7 N.m (62 lb in).
- Position the air cleaner assembly (1) onto the air cleaner adaptor (2).
- Push down on the air cleaner assembly in order to secure the assembly to the adaptor.
- Connect the MAF/IAT sensor electrical connector (4).
- Install the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(/chevrolet/cab-chassis-silverado-3500/2004-2007/remont/testing-diagnostics/#engine-controls-48l-53l-60l-introduction) .
- Loosen the clamp and separate the air cleaner outlet duct at the mass air flow/intake air temperature (MAF/IAT) sensor.
- Loosen the clamp and separate the air cleaner outlet duct from the throttle body.
- Remove the radiator inlet hose clamp from the outlet duct.
- Remove the air cleaner outlet duct.
- Install the air cleaner outlet duct.
- Install the air cleaner outlet duct to the throttle body.
- Install the air cleaner outlet duct to MAF/IAT sensor.
- Install the radiator inlet hose clamp to the outlet duct. NOTE: Refer to «Fastener Notice»(ref-197335-S17275608472005101100000) in Cautions and Notices.
- Tighten the air cleaner outlet duct clamps. Tighten: Tighten the clamps to 4 N.m (35 lb in).
Powertrain
The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM.
The following are some of the functions that the PCM controls
- The engine fueling
- The ignition control (IC)
- The knock sensor (KS) system
- The evaporative emissions (EVAP) system
- The secondary air injection (AIR) system (if equipped)
- The exhaust gas recirculation (EGR) system
- The automatic transmission functions
- The generator
- The A/C clutch control
- The cooling fan control
Powertrain Control Module Function
The powertrain control module (PCM) constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected.
Malfunction Indicator Lamp (MIL) Operation
The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON
Scheme 95
Scheme 96
The MIL indicates that an emissions related fault has occurred and vehicle service is required.
The following is a list of the modes of operation for the MIL
- The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate.
- The MIL turns OFF after the engine is started if a diagnostic fault is not present.
- The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate.
- The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter.
- When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON.
- When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON.
Trip
A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the powertrain control module (PCM), allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e., misfire).
Warm-Up Cycle
The powertrain control module (PCM) uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160°F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction.
Diagnostic Trouble Codes (DTCs)
The powertrain control module (PCM) is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the malfunction indicator lamp (MIL) or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records.
The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text.
There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type.
DTC Status
When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set.
Fuel Composition Sensor Description
The fuel composition sensor (FCS), or flex fuel sensor (service parts term), measures the ethanol-gasoline ratio of the fuel being used in a flexible fuel vehicle. Flexible fuel vehicles can be operated with a blend of ethanol and gasoline, up to 85 percent ethanol. In order to adjust the ignition timing and the fuel quantity to be injected, the engine management system requires information about the percentage of ethanol in the fuel.
The FCS uses quick-connect style fuel connections, an incoming fuel connection, and an outgoing fuel connection. The two connections have different diameters, to prevent incorrect attachment of the fuel lines. All fuel passes through the fuel composition sensor before continuing on to the fuel rail. The fuel composition sensor measures two different fuel related parameters, and sends an electrical signal to the powertrain control module (PCM) to indicate ethanol percentage, and fuel temperature.
The fuel composition sensor has a three-wire electrical harness connector. The three wires provide a ground circuit, a power source, and a signal output to the PCM. The power source is vehicle system voltage, +12 volts), and the ground circuit connects to chassis ground. The signal circuit carries both the ethanol percentage and fuel temperature within the same signal, on the same wire.
The FCS uses a microprocessor inside the sensor to measure the ethanol percentage and fuel temp, and change an output signal accordingly. The electrical characteristic of the FCS signal is a square-wave digital signal. The signal is both variable frequency and variable pulse width. The frequency of the signal indicates the ethanol percentage, and the pulse width indicates the fuel temperature. The PCM provides an internal pull-up to five volts on the signal circuit, and the FCS pulls the 5 volts to ground in pulses. The output frequency is linear to the percentage of ethanol content in the fuel. The normal range of operating frequency is between 50 and 150 Hertz, with 50 Hertz representing 0 percent ethanol, and 150 Hertz representing 100 percent ethanol. The normal pulse width range of the digital pulses is between 1 and 5 milliseconds, with 1 millisecond representing -40°C (-40°F), and 5 milliseconds representing 125°C (257°F).
The microprocessor inside the sensor is capable of a certain amount of self-diagnosis. An output frequency of 170 Hertz indicates either that the fuel is contaminated or contains methanol (it should not), or that an internal sensor electrical fault has been detected. Certain substances dissolved in the fuel can cause the fuel to be contaminated, raising the output frequency to be higher than the actual ethanol percentage should indicate. Examples of these substances include water, sodium chloride (salt), and methanol.
It should be noted that it is likely that the FCS will indicate a slightly lower ethanol percentage than what is advertised at the fueling station. This is not a fault of the sensor. The reason has to do with government requirements for alcohol-based motor fuels. Government regulations require that alcohol intended for use as motor fuel be DENATURED. This means that 100 percent pure ethanol is first denatured with approximately 41/2 percent gasoline, before being mixed with anything else. When an ethanol gasoline mixture is advertised as E85, the 85 percent ethanol was denatured before being blended with gasoline, meaning an advertised E85 fuel contains only about 81 percent ethanol. The FCS measures the actual percentage of ethanol in the fuel.
Throttle Actuator Control (TAC) System Description
The throttle actuator control (TAC) system delivers improved throttle response and greater reliability and eliminates the need for mechanical cable. The TAC system performs the following functions
- Accelerator pedal position (APP) sensing
- Throttle positioning to meet driver and engine demands
- Throttle position sensing
- Internal diagnostics
- Cruise control functions
- Manage TAC electrical power consumption
The TAC system components include the following
- The APP sensors
- The throttle body assembly
- The TAC module
- The powertrain control module (PCM)
Accelerator Pedal Position (APP) Sensor
The accelerator pedal assembly contains 2 individual accelerator pedal position (APP) sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits
- A 5-volt reference circuit
- A low reference circuit
- A signal circuit
The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied.
Throttle Body Assembly
The throttle body assembly consists of the throttle body, the throttle position (TP) sensors, and the throttle actuator motor. The throttle body functions similar to a conventional throttle body with the following exceptions
- An electric motor opens and closes the throttle valve.
- The throttle blade is spring loaded in both directions and the default position is slightly open.
- There are 2 individual TP sensors within the throttle body assembly.
The TP sensors 1 and 2 are potentiometer type sensors, each with the following circuits
- A 5-volt reference circuit
- A low reference circuit
- A signal circuit
The TP sensors are used to determine the throttle plate angle. The control module provides each TP sensor a 5-volt reference circuit and a low reference circuit. The TP sensors then provide the control module with signal voltage proportional to throttle plate movement. Both TP sensor signal voltages are low at closed throttle and increase as the throttle opens.
Throttle Actuator Control Module
The throttle actuator control (TAC) module is the control center for the throttle actuator control system. The TAC system is self-diagnosing and provides diagnostic information to the powertrain control module (PCM) through a dedicated serial data line. The TAC achieves throttle positioning by providing a pulse width modulated voltage to the TAC, as directed by the PCM.
Powertrain Control Module
The powertrain control module (PCM) determines the driver's intent, then calculates the appropriate throttle response. This information is sent to the throttle actuator control (TAC) module through a dedicated serial data line.
Normal Mode
During the operation of the throttle actuator control (TAC) system, several modes or functions are considered normal. The following modes may be entered during normal operation
- Minimum pedal value-At key-up the powertrain control module (PCM) updates the learned minimum pedal value.
- Minimum throttle position (TP) values-At key-up the PCM updates the learned minimum TP value. In order to learn the minimum TP value, the throttle blade is moved to the closed position.
- Ice break mode-If the throttle is not able to reach a predetermined minimum throttle position, the ice break mode is entered. During the ice break mode, the control module commands the maximum pulse width several times to the throttle actuator motor in the closing direction.
- Battery saver mode-After a predetermined time without engine RPM, the control module commands the battery saver mode. During the battery saver mode, the TAC module removes the voltage from the motor control circuits, which removes the current draw used to maintain the idle position and allows the throttle to return to the spring loaded default position.
Reduced Engine Power Mode
When the PCM detects a condition with the TAC system, the PCM may enter a reduced engine power mode. Reduced engine power may cause one or more of the following conditions
- Acceleration limiting-The control module will continue to use the accelerator pedal for throttle control; however, the vehicle acceleration is limited.
- Limited throttle mode-The control module will continue to use the accelerator pedal for throttle control; however, the maximum throttle opening is limited.
- Throttle default mode-The control module will turn off the throttle actuator motor and the throttle will return to the spring loaded default position.
- Forced idle mode-The control module will perform the following actions: Limit engine speed to idle by positioning throttle position, or by controlling fuel and spark if throttle is turned off. Ignore accelerator pedal input.
- Engine shutdown mode-The control module will disable fuel and de-energize the throttle actuator.
Fuel System Overview
The Fuel System is a returnless on-demand design. The fuel pressure regulator is a part of the fuel sender assembly, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions.
An electric turbine style fuel pump attaches to the fuel sender assembly inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir. The fuel pressure regulator, a part of the fuel sender assembly, maintains the correct fuel pressure to the fuel injection system. The fuel pump and sender assembly contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times.
Fuel Tanks
The fuel tanks store the fuel supply. The front fuel tank is located on the left side of the vehicle. On dual-tank applications, the secondary fuel tank is located in the rear of the vehicle above the spare tire. The fuel tanks are each held in place by 2 metal straps that attach to the frame. The fuel tanks are molded from high density polyethylene.
Fuel Fill Pipe
The fuel fill pipe has a built-in restrictor in order to prevent refueling with leaded fuel. When refueling dual tank applications, fuel is dispensed to both the front and rear fuel tanks at the same time. Once the fill vent is obstructed, fuel backs up the fill pipe and trips the dispensing nozzle. The front fuel tank vent runs into the rear tank to the top of the filler pipe assembly, which in turn vents to atmosphere. The fuel tank vent valves are connected and route to the canister to collect hydrocarbon emissions during operation of the vehicle.
Scheme 97
Scheme 98
Scheme 99
The fuel fill pipe has a tethered fuel filler cap. A torque-limiting device prevents the cap from being over tightened. To install the cap, turn the cap clockwise until you hear clicks. This indicates that the cap is correctly torqued and fully seated. A built-in device indicates that the fuel filler cap is fully seated. A fuel filler cap that is not fully seated may cause a malfunction in the emission system.
Scheme 100
The front fuel sender on dual tank applications consists of the following major components
- The fuel level sensor
- The fuel tank fuel pump module
- The fuel strainer
- The fuel filter
Scheme 101
The rear fuel sender on dual tank applications consists of the following major components
- The fuel level sensor (4)
- The FTP sensor (1)
- The rear fuel pump (2)
The fuel sender assembly on single tank applications consists of the following major components
- The fuel level sensor
- The fuel tank pressure (FTP) sensor
- The fuel tank fuel pump module
- The fuel strainer
- The fuel filter
Fuel Level Sensor
The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (I/P) cluster. This information is used for the I/P fuel gage and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics.
Fuel Pump
The fuel pump is mounted in the fuel sender assembly reservoir. The fuel pump is an electric high pressure pump. Fuel is pumped to the fuel rail at a specified flow and pressure. The fuel pump delivers a constant flow of fuel to the engine during low fuel conditions and aggressive vehicle maneuvers. The powertrain control module (PCM) controls the electric fuel pump operation through a fuel pump relay. The fuel pump flex pipe acts to dampen the fuel pulses and noise generated by the fuel pump.
Rear Fuel Pump (Dual Tank Applications Only)
On dual tank applications, the rear fuel pump is located in the rear fuel tank. The rear fuel pump is powered by a secondary fuel pump relay when the fuel level drops below a predetermined value. Fuel is transferred from the rear fuel tank to the front fuel tank in order to ensure all of the usable fuel volume is available to the front fuel pump. The secondary fuel pump relay supply voltage is received from the primary fuel pump relay when the front fuel pump is energized.
Fuel Strainer
The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment.
Fuel Filter
The fuel filter is contained in the fuel sender assembly inside the fuel tank. the paper filter element of the fuel filter traps particles in the fuel that may damage the fuel injection system. The fuel filter housing is made to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. There is no service interval for fuel filter replacement.
Nylon Fuel Pipes
| CAUTION | Refer to Fuel and EVAP Pipe Caution in Cautions and Notices. |
Nylon pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. There are 3 sizes of nylon pipes used: 9.5 mm (3/8 in) ID for the fuel supply, 7.6 mm (5/16 in) ID for the fuel return, and 12.7 mm (1/2 in) ID for the vent. Heat resistant rubber hose or corrugated plastic conduit protects the sections of the pipes that are exposed to chafing, to high temperatures, or to vibration.
Nylon fuel pipes are somewhat flexible and can be formed around gradual turns under the vehicle. However, if nylon fuel pipes are forced into sharp bends, the pipes kink and restrict the fuel flow. Also, once exposed to fuel, nylon pipes may become stiffer and are more likely to kink if bent too far. Take special care when working on a vehicle with nylon fuel pipes.
Quick-Connect Fittings
Quick-connect fittings provide a simplified means of installing and connecting fuel system components. The fittings consist of a unique female connector and a compatible male pipe end. O-rings, located inside the female connector, provide the fuel seal. Integral locking tabs inside the female connector hold the fittings together.
On-Board Refueling Vapor Recovery System (ORVR)
The On-Board Refueling Vapor Recovery System (ORVR) is an on-board vehicle system designed to recover fuel vapors during the vehicle refueling operation. The flow of liquid fuel down the fuel filler pipe provides a liquid seal which prevents vapor from leaving the fuel filler pipe. An evaporative emission (EVAP) pipe transports the fuel vapor to the EVAP canister for use by the engine.
Fuel Pipe O-Rings
O-rings seal the threaded connections in the fuel system. Fuel system O-ring seals are made of special material. Service the O-ring seals with the correct service part.
Scheme 102
The fuel rail assembly attaches to the engine intake manifold. The fuel rail assembly performs the following functions
- Positions the injectors (3) in the intake manifold
- Distributes fuel evenly to the injectors
- Integrates the fuel dampener (2) into the fuel metering system
Fuel Injectors
The fuel injector assembly is a solenoid device controlled by the powertrain control module (PCM) that meters pressurized fuel to a single engine cylinder. The PCM energizes the injector solenoid to open a normally closed ball valve. This allows the fuel to flow into the top of the injector, past the ball valve, and through a director plate at the injector outlet. The director plate has machined holes that control the fuel flow, generating a spray of finely atomized fuel at the injector tip. Fuel from the injector tip is directed at the intake valve, causing the fuel to become further atomized and vaporized before entering the combustion chamber. This fine atomization improves fuel economy and emissions.
Fuel Pressure Regulator
The fuel pressure regulator is contained in the fuel sender assembly.
Fuel Metering Modes of Operation
The powertrain control module (PCM) monitors voltages from several sensors in order to determine how much fuel to give the engine. The PCM controls the amount of fuel delivered to the engine by changing the fuel injector pulse width. The fuel is delivered under one of several modes.
Starting Mode
When the ignition is first turned ON, the PCM energizes the fuel pump relay for 2 seconds. This allows the fuel pump to build pressure in the fuel system. The PCM calculates the air/fuel ratio based on inputs from the engine coolant temperature (ECT), mass air flow (MAF), manifold absolute pressure (MAP), and throttle position (TP) sensors. The system stays in starting mode until the engine speed reaches a predetermined RPM.
Clear Flood Mode
If the engine floods, clear the engine by pressing the accelerator pedal down to the floor and then crank the engine. When the TP sensor is at wide open throttle (WOT), the PCM reduces the fuel injector pulse width in order to increase the air to fuel ratio. The PCM holds this injector rate as long as the throttle stays wide open and the engine speed is below a predetermined RPM. If the throttle is not held wide open, the PCM returns to the starting mode.
Run Mode
The run mode has 2 conditions called Open Loop and Closed Loop. When the engine is first started and the engine speed is above a predetermined RPM, the system begins Open Loop operation. The PCM ignores the signal from the heated oxygen sensors (HO2S). The PCM calculates the air/fuel ratio based on inputs from the ECT, MAF, MAP, and TP sensors. The system stays in Open Loop until meeting the following conditions
- Both front HO2S have varying voltage output, showing that both HO2S are hot enough to operate properly.
- The ECT sensor is above a specified temperature.
- A specific amount of time has elapsed after starting the engine.
Specific values for the above conditions exist for each different engine, and are stored in the electrically erasable programmable read-only memory (EEPROM). The system begins Closed Loop operation after reaching these values. In Closed Loop, the PCM calculates the air/fuel ratio, injector ON time, based upon the signal from various sensors, but mainly from the HO2S. This allows the air/fuel ratio to stay very close to 14.7:1.
Acceleration Mode
When the driver pushes on the accelerator pedal, air flow into the cylinders increases rapidly. To prevent possible hesitation, the PCM increases the pulse width to the injectors to provide extra fuel during acceleration. This is also known as power enrichment. The PCM determines the amount of fuel required based upon the TP, the ECT, the MAP, the MAF, and the engine speed.
Deceleration Mode
When the driver releases the accelerator pedal, air flow into the engine is reduced. The PCM monitors the corresponding changes in the TP, the MAP, and the MAF. The PCM shuts OFF fuel completely if the deceleration is very rapid, or for long periods, such as long, closed-throttle coast-down. The fuel shuts OFF in order to prevent damage to the catalytic converters.
Battery Voltage Correction Mode
When the battery voltage is low, the PCM compensates for the weak spark delivered by the ignition system in the following ways
- Increasing the amount of fuel delivered
- Increasing the idle RPM
- Increasing the ignition dwell time
Fuel Cutoff Mode
The PCM cuts OFF fuel from the fuel injectors when the following conditions are met in order to protect the powertrain from damage and improve driveability
- The ignition is OFF. This prevents engine run-on.
- The ignition is ON but there is no ignition reference signal. This prevents flooding or backfiring.
- The engine speed is too high, above red line.
- The vehicle speed is too high, above rated tire speed.
- During an extended, high speed, closed throttle coast down-This reduces emissions and increases engine braking.
- During extended deceleration, in order to prevent damage to the catalytic converters
Fuel Trim
The powertrain control module (PCM) controls the air/fuel metering system in order to provide the best possible combination of driveability, fuel economy, and emission control. The PCM monitors the heated oxygen sensor (HO2S) signal voltage while in Closed Loop and regulates the fuel delivery by adjusting the pulse width of the fuel injectors based on this signal. The ideal fuel trim values are around 0 percent for both short term and long term fuel trim. A positive fuel trim value indicates the PCM is adding fuel in order to compensate for a lean condition by increasing the pulse width. A negative fuel trim value indicates that the PCM is reducing the amount of fuel in order to compensate for a rich condition by decreasing the pulse width. A change made to the fuel delivery changes the short term and long term fuel trim values. The short term fuel trim values change rapidly in response to the HO2S signal voltage. These changes fine tune the engine fueling. The long term fuel trim makes coarse adjustments to the fueling in order to re-center and restore control to short term fuel trim. A scan tool can be used to monitor the short term and long term fuel trim values. The long term fuel trim diagnostic is based on an average of several of the long term speed load learn cells. The PCM selects the cells based on the engine speed and engine load. If the PCM detects an excessive lean or rich condition, the PCM will set a fuel trim diagnostic trouble code (DTC).
The fuel tank stores the fuel supply. The electric fuel pump sends fuel through an in-line fuel filter to the fuel rail assembly. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injectors. The fuel pressure regulator keeps fuel available to the injectors at a regulated pressure. A separate pipe returns unused fuel to the fuel tank.
Fuel Tank
The fuel tanks store the fuel supply. The front fuel tank is located on the left side of the vehicle. On duel-tank applications, the secondary fuel tank is located in the rear of the vehicle. The fuel tanks are each held in place by two metal straps that attach to the frame. The fuel tanks are molded from high density polyethylene.
The fuel fill pipe has a built-in restrictor in order to prevent refueling with leaded fuel. Once the fill vent is obstructed, fuel backs up the fill pipe and trips the dispensing nozzle. The front fuel tank vent runs into the rear tank to the top of the filler pipe assembly, which in turn vents to atmosphere. The fuel tank vent valves are connected and route to the canister to collect hydrocarbon emissions during operation of the vehicle.
Scheme 103
The fuel sender assembly consists of the following major components
- The fuel sender assembly (2)
- The fuel strainer (3)
- The fuel pump (4)
The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. On models that are equipped with a single fuel tank, the fuel level sensor is wired directly to the instrument panel (I/P) cluster. On models equipped with dual fuel tanks, both fuel level sensors are wired to the powertrain control module (PCM). The PCM calculates the total fuel level in both tanks. The instrument panel (I/P) fuel gage displays the total fuel level in both fuel tanks.
Scheme 104
The fuel pump is mounted in the fuel sender assembly. The fuel pump is an electric high pressure pump. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injectors. Excess fuel from the fuel rail assembly returns to the fuel tanks through the fuel return pipe. The fuel pump delivers a constant flow of fuel to the engine even during low fuel conditions. The powertrain control module (PCM) controls the electric fuel pump operation through a fuel pump relay. The fuel pump flex pipe acts to dampen the fuel pulses and noise generated by the fuel pump.
Secondary Fuel Pump - Dual Tanks
The secondary fuel pump is a low pressure electric transfer pump. The secondary fuel pump is mounted outside the fuel tank on the left side of the body crossmember. The secondary fuel pump transfers fuel from the secondary fuel tank to the primary fuel tank when commanded by the powertrain control module (PCM). The PCM grounds the secondary fuel pump relay control circuit. Fuel level is continuously monitored in both tanks by the PCM. When the fuel level in the primary tank is approximately 2 gallons lower than that in the secondary tank, the secondary fuel pump is energized and approximately 4 gallons of fuel is transferred to the primary tank. The above actions continue until the primary tank fuel level is low enough that it will accept all of the remaining fuel in the secondary tank, at which time the secondary fuel pump is energized until the secondary tank is empty.
Scheme 105
The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. The fuel strainer is self-cleaning and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or water.
Scheme 106
The fuel filter is located on the fuel feed pipe, between the fuel pump and the fuel injectors. The paper filter element (2) traps particles in the fuel that may damage the fuel injection system. The filter housing (1) is made to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. There is no service interval for fuel filter replacement. Replace a restricted fuel filter.
Fuel Feed and Return Pipes
The fuel feed pipe carries fuel from the fuel tank to the fuel rail assembly. The fuel return pipe carries fuel from the fuel rail assembly back to the fuel tanks. The fuel pipes consist of 2 sections
- The rear fuel pipe assemblies are located from the top of the fuel tank to the chassis fuel pipes. The rear fuel pipes are constructed of nylon.
- The chassis fuel pipes are located under the vehicle and connect the rear fuel pipes to the fuel rail pipes. The chassis fuel pipes are constructed of steel.
Nylon pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. Heat resistant rubber hose or corrugated plastic conduit protect the sections of the pipes that are exposed to chafing, high temperature, or vibration.
Nylon fuel pipes are somewhat flexible and can be formed around gradual turns under the vehicle. However, if nylon fuel pipes are forced into sharp bends, the pipes kink and restrict the fuel flow. Also, once exposed to fuel, nylon pipes may become stiffer and are more likely to kink if bent too far. Take special care when working on a vehicle with nylon fuel pipes.
Quick-connect fittings provide a simplified means of installing and connecting fuel system components. The fittings consist of a unique female connector and a compatible male pipe end. O-rings, located inside the female connector, provide the fuel seal. Integral locking tabs inside the female connector hold the fittings together.
O-rings seal the connections in the fuel system. Fuel system O-ring seals are made of special material. Service the O-ring seals with the correct service part.
Scheme 107
The fuel rail assembly attaches to the engine intake manifold. The fuel rail assembly performs the following functions
- Positions the injectors (3) in the intake manifold
- Distributes fuel evenly to the injectors
- Integrates the fuel pressure regulator (2) with the fuel metering system
Scheme 108
The Multec 2 fuel injector assembly is a solenoid device, controlled by the powertrain control module (PCM), that meters pressurized fuel to a single engine cylinder. The PCM energizes the high-impedance (12.0 ohms) injector solenoid (2) to open a normally closed ball valve (3). This allows fuel to flow into the top of the injector, past the ball valve, and through a director plate at the injector outlet. The director plate has 2 machined holes that control the fuel flow, generating a spray of finely atomized fuel at the injector tip. Fuel from the injector tip is directed at the intake valve, causing it to become further atomized and vaporized before entering the combustion chamber. This fine atomization improves fuel economy and emissions.
Scheme 109
The fuel pressure regulator is a vacuum operated diaphragm relief valve. The diaphragm has fuel pressure on one side and regulator spring pressure and intake manifold vacuum on the other side. The fuel pressure regulator compensates for changes in intake manifold vacuum by changing the fuel pressure. In this way, the fuel pressure regulator maintains a constant pressure differential across the fuel injectors under all operating conditions.
The powertrain control module (PCM) monitors voltages from several sensors in order to determine how much fuel to give the engine. The PCM controls the amount of fuel delivered to the engine by changing the fuel injector pulse width. The fuel is delivered under one of several modes.
When the ignition is first turned ON, the powertrain control module (PCM) energizes the fuel pump relay for 2 seconds. This allows the fuel pump to build pressure in the fuel system. The PCM calculates the air/fuel ratio based on inputs from the engine coolant temperature (ECT), mass air flow (MAF), manifold absolute pressure (MAP), and throttle position (TP) sensors. The system stays in starting mode until the engine speed reaches a predetermined RPM.
If the engine floods, clear the engine by pressing the accelerator pedal down to the floor and then crank the engine. When the throttle position (TP) sensor is at wide open throttle, the powertrain control module (PCM) reduces the fuel injector pulse width in order to increase the air to fuel ratio. The PCM holds this injector rate as long as the throttle stays wide open and the engine speed is below a predetermined RPM. If the throttle is not held wide open, the PCM returns to the starting mode.
The run mode has 2 conditions called Open Loop and Closed Loop. When the engine is first started and the engine speed is above a predetermined RPM, the system begins Open Loop operation. The powertrain control module (PCM) ignores the signal from the heated oxygen sensor (HO2S). The PCM calculates the air/fuel ratio based on inputs from the engine coolant temperature (ECT), mass air flow (MAF), manifold absolute pressure (MAP), and throttle position (TP) sensors. The system stays in Open Loop until meeting the following conditions
- Both HO2S have varying voltage output, showing that they are hot enough to operate properly.
- The ECT sensor is above a specified temperature.
- A specific amount of time has elapsed after starting the engine.
Specific values for the above conditions exist for each different engine, and are stored in the electrically erasable programmable read-only memory (EEPROM). The system begins Closed Loop operation after reaching these values. In Closed Loop, the PCM calculates the air/fuel ratio (injector on-time) based upon the signal from various sensors, but mainly from the HO2S. This allows the air/fuel ratio to stay very close to 14.7:1.
When the driver pushes on the accelerator pedal, air flow into the cylinders increases rapidly. To prevent possible hesitation, the powertrain control module (PCM) increases the pulse width to the injectors to provide extra fuel during acceleration. This is also known as power enrichment. The PCM determines the amount of fuel required based upon the throttle position, the coolant temperature, the manifold air pressure, the mass air flow, and the engine speed.
When the driver releases the accelerator pedal, air flow into the engine is reduced. The powertrain control module (PCM) monitors the corresponding changes in throttle position, manifold air pressure, and mass air flow. The PCM shuts off fuel completely if the deceleration is very rapid, or for long periods, such as long, closed-throttle coast-down. The fuel shuts off in order to prevent damage to the catalytic converters.
When the battery voltage is low, the powertrain control module (PCM) compensates for the weak spark delivered by the ignition system in the following ways
- Increasing the amount of fuel delivered
- Increasing the idle RPM
- Increasing the ignition dwell time
The PCM cuts off fuel from the fuel injectors when the following conditions are met in order to protect the powertrain from damage and improve driveability
- The ignition is OFF. This prevents engine run-on.
- The ignition is ON but there is no ignition reference signal. This prevents flooding or backfiring.
- The engine speed is too high, above red line.
- The vehicle speed is too high, above rated tire speed.
- During an extended, high speed, closed throttle coast down-This reduces emissions and increases engine braking.
- During extended deceleration, in order to prevent damage to the catalytic converters
The powertrain control module (PCM) controls the air/fuel metering system in order to provide the best possible combination of driveability, fuel economy, and emission control. The PCM monitors the heated oxygen sensor (HO2S) signal voltage while in Closed Loop and regulates the fuel delivery by adjusting the pulse width of the fuel injectors based on this signal. The ideal fuel trim values are around 0 percent for both short term and long term fuel trim. A positive fuel trim value indicates the PCM is adding fuel in order to compensate for a lean condition by increasing the pulse width. A negative fuel trim value indicates that the PCM is reducing the amount of fuel in order to compensate for a rich condition by decreasing the pulse width. A change made to the fuel delivery changes the short term and long term fuel trim values. The short term fuel trim values change rapidly in response to the HO2S signal voltage. These changes fine tune the engine fueling. The long term fuel trim makes coarse adjustments to the fueling in order to re-center and restore control to short term fuel trim. A scan tool can be used to monitor the short term and long term fuel trim values. The long term fuel trim diagnostic is based on an average of several of the long term speed load learn cells. The PCM selects the cells based on the engine speed and engine load. If the PCM detects an excessive lean or rich condition, the PCM will set a fuel trim diagnostic trouble code (DTC).
EVAP System Operation
The evaporative emission (EVAP) control system limits fuel vapors from escaping into the atmosphere. Fuel tank vapors are allowed to move from the fuel tank, due to pressure in the tank, through the vapor pipe, into the EVAP canister. Carbon in the canister absorbs and stores the fuel vapors. Excess pressure is vented through the vent line and EVAP vent solenoid valve to the atmosphere. The EVAP canister stores the fuel vapors until the engine is able to use them. At an appropriate time, the control module will command the EVAP purge solenoid valve ON, allowing engine vacuum to be applied to the EVAP canister. With the EVAP vent solenoid valve OFF, fresh air is drawn through the vent solenoid valve and the vent line to the EVAP canister. Fresh air is drawn through the canister, pulling fuel vapors from the carbon. The air/fuel vapor mixture continues through the EVAP purge pipe and EVAP purge solenoid valve into the intake manifold to be consumed during normal combustion. The control module uses several tests to determine if the EVAP system is leaking.
Large Leak Test
This tests for large leaks and blockages in the evaporative emission (EVAP) system. The control module commands the EVAP vent solenoid valve ON and commands the EVAP purge solenoid valve ON, with the engine running, allowing engine vacuum into the EVAP system. The control module monitors the fuel tank pressure (FTP) sensor voltage to verify that the system is able to reach a predetermined level of vacuum within a set amount of time. The control module then commands the EVAP purge solenoid valve OFF, sealing the system, and monitors the vacuum level for decay. If the control module does not detect that the predetermined vacuum level was achieved, or the vacuum decay rate is more than a calibrated level on 2 consecutive tests, DTC P0455 will set.
Small Leak Test
The engine off natural vacuum (EONV) diagnostic is the small-leak detection diagnostic for the evaporative emission (EVAP) system. While previous leak detection methods were performed with the engine running, the EONV diagnostic monitors the EVAP system pressure or vacuum with the ignition OFF. Because of this, it may be normal for the control module to remain active for up to 40 minutes after the ignition is turned OFF. This is important to remember when performing a parasitic draw test on vehicles equipped with EONV.
The EONV utilizes the temperature changes in the fuel tank immediately following a drive cycle to use the naturally occurring vacuum or pressure in the fuel tank. When the vehicle is driven, the temperature rises in the tank. After the vehicle is parked, the temperature in the tank continues to rise for a period of time, then starts to drop. The EONV diagnostic relies on this temperature change and the corresponding pressure change in a sealed system, to determine if an EVAP system leak is present.
The EONV diagnostic is designed to detect leaks as small as 0.51 mm (0.020 in). The diagnostic can determine if a small leak is present based on vacuum or pressure readings in the EVAP system. When the system is sealed, a finite amount of pressure or vacuum will be observed. When a 0.51 mm (0.020 in) leak is present, often little or no pressure or vacuum is observed. If the test reports a failing value, DTC P0442 will set.
Canister Vent Restriction Test
If the evaporative emission (EVAP) vent system is restricted, fuel vapors will not be properly purged from the EVAP canister. The control module tests this by commanding the EVAP purge solenoid valve ON, commanding the EVAP vent solenoid valve OFF, and monitoring the fuel tank pressure (FTP) sensor for an increase in vacuum. If the vacuum increases more than a calibrated value, DTC P0446 will set.
Purge Solenoid Valve Leak Test
If the evaporative emission (EVAP) purge solenoid valve does not seal properly fuel vapors could enter the engine at an undesired time, causing driveability concerns. The control module tests for this by commanding the EVAP purge solenoid valve OFF and the vent solenoid valve ON, sealing the system, and monitors the fuel tank pressure (FTP) for an increase in vacuum. If the control module detects that the EVAP system vacuum increases above a calibrated value, DTC P0496 will set.
Check Gas Cap Message
The powertrain control module (PCM) sends a class 2 message to the driver information center (DIC) illuminating the Check Gas Cap message when any of the following occur
- A malfunction in the evaporative emission (EVAP) system and a large leak test fails
- A malfunction in the EVAP system and a small leak test fails
EVAP System Components
The evaporative emission (EVAP) system consists of the following components
EVAP Canister
The canister is filled with carbon pellets used to absorb and store fuel vapors. Fuel vapor is stored in the canister until the control module determines that the vapor can be consumed in the normal combustion process.
EVAP Purge Solenoid Valve
The EVAP purge solenoid valve controls the flow of vapors from the EVAP system to the intake manifold. The purge solenoid valve opens when commanded ON by the control module. This normally closed valve is pulse width modulated (PWM) by the control module to precisely control the flow of fuel vapor to the engine. The valve will also be opened during some portions of the EVAP testing, allowing engine vacuum to enter the EVAP system.
EVAP Vent Solenoid Valve
The EVAP vent solenoid valve controls fresh airflow into the EVAP canister. The valve is normally open. The control module commands the valve ON, closing the valve during some EVAP tests, allowing the system to be tested for leaks.
Fuel Tank Pressure Sensor
The fuel tank pressure (FTP) sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure.
EVAP Service Port
The EVAP service port is located in the EVAP purge pipe between the EVAP purge solenoid valve and the EVAP canister. The service port is identified by a green colored cap.
Electronic Ignition (EI) System Description
The electronic ignition (EI) system is responsible for producing and controlling a high energy secondary spark. This spark is used to ignite the compressed air/fuel mixture at precisely the correct time. This provides optimal performance, fuel economy, and control of exhaust emissions. This ignition system consists of a separate ignition coil connected to each spark plug by a short secondary wire. The driver modules within each coil assembly are commanded ON/OFF by the powertrain control module (PCM). The PCM primarily uses engine speed and position information from the crankshaft and camshaft position (CMP) sensors to control the sequence, dwell, and timing of the spark. The EI system consists of the following components
Crankshaft Position (CKP) Sensor
The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution.
Crankshaft Reluctor Wheel
The crankshaft reluctor wheel is mounted on the rear of the crankshaft. The wheel is comprised of four 90 degree segments. Each segment represents a pair of cylinders at TDC, and is further divided into six 15 degree segments. Within each 15 degree segment is a notch of 1 of 2 different sizes. Each 90 degree segment has a unique pattern of notches. This is known as pulse width encoding. This pulse width encoded pattern allows the PCM to quickly recognize which pair of cylinders are at top dead center (TDC). The reluctor wheel is also a dual track-or mirror image-design. This means there is an additional wheel pressed against the first, with a gap of equal size to each notch of the mating wheel. When one sensing element of the CKP sensor is reading a notch, the other is reading a set of teeth. The resulting signals are then converted into a digital square wave output by the circuitry within the CKP sensor.
Camshaft Position (CMP) Sensor
The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP.
Camshaft Reluctor Wheel
The camshaft reluctor wheel is either pressed onto the camshaft or part of the timing gear depending on the application. The feature-or target- is read in a radial or axial fashion respectively. The wheel is a smooth track, half of which is of a lower profile than the other half. This feature allows the CMP sensor to supply a signal as soon as the key is turned ON, since the CMP sensor reads the track profile, instead of a notch.
Ignition Coils
Each ignition coil has an ignition 1 feed and a ground. The PCM supplies a low reference and an ignition control (IC) circuit. Each ignition coil contains a solid state driver module. The PCM will command the IC circuit ON, this allows the current to flow through the primary coil windings for the appropriate time or dwell. When the PCM commands the IC circuit OFF, this will interrupt current flow through the primary coil windings. The magnetic field created by the primary coil windings will collapse across the secondary coil windings, which induces a high voltage across the spark plug electrodes. The coils are current limited to prevent overloading if the IC current is held high too long. The spark plugs are connected to their respective coils by a short secondary wire. The spark plugs are tipped with iridium for long life and efficiency.
Powertrain Control Module (PCM)
The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following
- The throttle position (TP) sensor
- The engine coolant temperature (ECT) sensor
- The mass air flow (MAF) sensor
- The intake air temperature (IAT) sensor
- The vehicle speed sensor (VSS)
- The transmission gear position or range information sensors
- The engine knock sensors (KS)
Modes of Operation
There is one normal mode of operation, with the spark under PCM control. If the CKP pulses are lost the engine will not run. The loss of a CMP signal may result in a longer crank time since the PCM cannot determine which stroke the pistons are on. Diagnostic trouble codes are available to accurately diagnose the ignition system with a scan tool.
Purpose
The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock.
Sensor Description
This knock sensor (KS) system uses one or 2 broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependent upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing.
One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters.
Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal.
In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output.
Air Intake System Description
The primary function of the air intake system is to provide filtered air to the engine. The system uses a cleaner element mounted in a housing. The cleaner housing is remotely mounted and uses intake ducts to route the incoming air into the throttle body. The secondary function of the air intake system is to muffle air induction noise. This is achieved through the use of resonators attached to the air intake ducts. the resonators are tuned to the specific powertrain. The mass air flow (MAF) sensor is attached to the outlet of the air cleaner housing. The air cleaner life indicator is located on an intake duct between the air cleaner housing and the throttle plate.
Special Tools
Special Tools Illustration Tool Number/Description GE 41415-50 Fuel Tank Cap Adapter J 23738-A Mityvac J 26792 Spark Tester J 34142-B Test Lamp J 34730-E Fuel Pressure Gage Kit J 34730-1A Fuel Pressure Gage J 34730-405 Injector Test Lamp J 35616-A Connector Test Adapter Kit J 35800-A Fuel Injector Cleaner J 37287 Fuel Line Shut-Off Adapters J 38522 Variable Signal Generator J 39021 Fuel Injector Coil and Balance Tester J 39021-380 Fuel Injector Test Harness J 41413-200 Evaporative Emissions System Tester (EEST) J 41413-VLV EVAP Service Port Vent Fitting J 41413-SPT High Intensity White Light J 41415-30 Fuel Tank Adapter J 41415-40 Fuel Tank Cap Adapter J 41416 Ultrasonic Leak Detector J 41769 Fuel Line Disconnect Tool Set J 42598 Vehicle Data Recorder J 42873-1 3/8 Fuel Line Shut-Off Adapter J 42873-2 5/16 Fuel Line Shut-Off Adapter J 42964-1 3/8 Fuel Pipe Shut-Off Valve J 42964-2 5/16 Fuel Pipe Shut-Off Valve J 43178 Fuel Line Disconnect Tool J 43244 Relay Puller Pliers J 44402 Fuel Tank Sending Unit Wrench J 44175 Fuel Composition Tester J 44602 Fuel Injector Test Adapter J 44603 Fuel Injector Test Lamp J 45004 Fuel Tank Drain Hose J 45722 Fuel Sender Lock Ring Wrench J 46363 Fuel Line Release Tool Tech 2 Kit 7000081
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See also:
• DTC P0315
• Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L (RPO LQ4))
• Fuel Pressure Relief Procedure
• Air Cleaner Resonator Outlet Duct Replacement
• Quick Connect Fitting(s) Service (Metal Collar)
• Special Tools
• Fuel Tank Draining Procedure (5.3L (L59) Engine)
• Ignition System Specifications
• CKP System Variation Learn Procedure