Engine Controls - Remove/install/overhaul - 3.8l Chevrolet Camaro IV

INTRODUCTION

Removal, overhaul and installation procedures (when given by manufacturer) are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be supplied.

POWERTRAIN CONTROL MODULE (PCM)

STATIC CHARGE

Scheme 11

Note. Before replacing PCM, carefully inspect all wiring and control components. Failure to test for short circuits may result in repeated PCM failure due to shorts and Quad-Driver failure. To prevent internal damage to PCM, ensure ignition switch is in OFF position when connecting or disconnecting PCM connectors or any electrical components.

Note. When replacing defective PCM, remove knock sensor module or PROM from defective PCM. New PCM does not come equipped with knock sensor module or PROM (if applicable). Install knock sensor module or PROM into new PCM.

Removal

Ensure ignition switch is in OFF position. Disconnect negative battery cable. Remove electrical connectors from PCM. Remove PCM from vehicle. Remove access cover and remove knock sensor module or PROM (if applicable) from PCM.

Installation

Install knock sensor module or PROM (if applicable) in new PCM. Install access cover. Install PCM into vehicle. Connect electrical connectors to PCM. Reconnect negative battery cable.

Disconnect negative battery cable. Remove PCM from vehicle. See POWERTRAIN CONTROL MODULE (PCM) . Position PCM with access cover up. Remove access cover from PCM. Using thumb and forefinger, squeeze both ends of PROM inward (outward on some models) and pull PROM up from access hole.

Note. Note reference notch locations in PROM and PCM for reassembly reference.

1. Ensure new PROM has same service number as original. Position PROM squarely over PCM PROM access hole. Press on outer edges of PROM until PROM is firmly seated in PCM. NOTE: Ensure reference notches in both PCM and PROM are properly aligned. If PROM is installed backward, PROM will be destroyed when ignition is turned on.
2. Install PROM access cover on PCM. Install PCM in vehicle. See «POWERTRAIN CONTROL MODULE (PCM)»(/chevrolet/camaro/iv-1992-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-38l__powertrain-control-module-pcm) . Start engine and enter diagnostics. See appropriate TESTS W/CODES article. Check for diagnostic trouble codes. See appropriate TESTS W/CODES article Xfor code identification.
3. If code(s) sets, PROM is either not fully seated in PCM or installed backward, has bent pins or is defective. If bent pins crack when trying to straighten, replace PROM. If PROM is installed backward or is defective, replace PROM.

Removal & Installation

1. Disconnect negative battery cable. Remove PCM from vehicle. See «POWERTRAIN CONTROL MODULE (PCM)»(/chevrolet/camaro/iv-1992-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-38l__powertrain-control-module-pcm) . Position PCM with access cover up. Remove access cover from PCM.
2. Using thumb and forefinger, squeeze both ends of knock sensor module inward and pull module up from access hole. To install, reverse removal procedure. Ensure module latches into holder in PCM.

1. Disconnect negative battery cable. Disconnect 14-way connector at ignition control module. Disconnect spark plug wires from coil pack. Remove 6 screws retaining coils to ignition control module. Tilt coil assembly back, and disconnect connectors between ignition coil and module. Remove coil pack.
2. Remove nuts and washers securing ignition control module to bracket. Remove ignition control module. To install, reverse removal procedure. Tighten retaining screws and nuts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/camaro/iv-1992-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-38l) .

Disconnect negative battery cable. Disconnect sensor harness connector. Remove camshaft position sensor bolt and remove sensor. To install, reverse removal procedure. Tighten sensor bolt to specification. See TORQUE SPECIFICATIONS .

1. Disconnect negative battery cable. Remove serpentine belt from crankshaft pulley. Raise vehicle on hoist. Remove right front tire and wheel assembly. Remove right inner fender access cover.
2. Using 28-mm socket, remove crankshaft harmonic balancer bolt. Using Balancer Remover (J-38197), remove harmonic balancer. Remove crankshaft position sensor shield (DO NOT use pry bar). (Scheme 12) Disconnect crankshaft position sensor harness connector. Remove crankshaft position sensor from engine block.
3. To install, reverse removal procedure. Apply Thread Sealer (GM 1052080) to threads of harmonic balancer bolt. Tighten sensor and harmonic balancer bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/camaro/iv-1992-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-38l).

Scheme 12

Disconnect negative battery cable. Disconnect spark plug wires from coil pack. Remove 6 screws retaining coils to ignition control module. Tilt coil assembly back, and disconnect connectors between ignition coil and module. Remove coil pack. To install, reverse removal procedure. Tighten retaining screws to specification. See TORQUE SPECIFICATIONS .

FUEL PRESSURE RELIEF

1. Fuel system is under pressure. Relieve pressure before servicing fuel system. Fuel pressure may be relieved using one of 2 different methods.
2. First method. Disconnect fuel pump connector. Start engine and allow to run until it stops. Operate starter for 3 seconds to remove remaining fuel from fuel lines. Reconnect fuel pump once repair is complete.
3. Second method. Install Fuel Pressure Gauge (SA9127E for Saturn or J-34730-1 for all other models) on fuel pressure test port. When installing fuel pressure gauge, wrap shop towel around pressure connection to absorb fuel leakage. Place gauge bleed hose in container. Open bleed valve to bleed fuel pressure.

THROTTLE BODY

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/camaro/iv-1992-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-38l__fuel-pressure-relief) . Disconnect negative battery cable. Remove air intake ducts. Disconnect and mark electrical connections and vacuum hoses from throttle body. Disconnect control cables from throttle body.
2. Drain cooling system and remove coolant hoses to throttle body (if applicable). Remove throttle body retaining bolts. Remove throttle body and gasket.

Note. Identification number is stamped on throttle body. Use identification number to order replacement components.

1. To install, reverse removal procedure using NEW gasket. Tighten retaining bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/camaro/iv-1992-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-38l) . Refill cooling system (if drained).
2. If installing new Idle Air Control (IAC) valve, ensure IAC pintle length setting is adjusted before installation. See «IDLE AIR»(/chevrolet/camaro/iv-1992-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-38l__idle-air-control-iac-valve) CONTROL (IAC) VALVE. Adjust idle speed and TP sensor (if removed, and if adjustable). See ADJUSTMENTS article.

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/camaro/iv-1992-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-38l__fuel-pressure-relief) . Disconnect negative battery cable. Remove air intake duct (if necessary). Disconnect pressure regulator vacuum hose. Remove fuel return line and "O" ring from pressure regulator.
2. Remove pressure regulator screws. Remove pressure regulator from fuel rail. Remove pressure regulator retainer and spacer assembly from fuel rail (if equipped). Remove fuel inlet "O" ring from pressure regulator. Remove and discard filter screen if dirty.

To install, reverse removal procedure. DO NOT reuse "O" rings. Lubricate fuel inlet "O" ring with oil and install in regulator. Replace filter screen as necessary. Tighten screws to specification. See TORQUE SPECIFICATIONS .

FUEL RAIL & INJECTORS

Note. If injector is replaced, ensure replacement injector has the same part number as injector removed.

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/camaro/iv-1992-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-38l__fuel-pressure-relief). Disconnect negative battery cable. Remove air intake duct (if necessary).
2. Disconnect vacuum hose at fuel pressure regulator. Disconnect and plug fuel return line at pressure regulator. Disconnect and plug fuel inlet line at fuel rail. Disconnect electrical connectors from injectors.
3. Remove fuel rail retaining bolts. Remove fuel rail from intake manifold using equal force on both sides of fuel rail. (Scheme 13)and (Scheme 14). Remove injector-to-fuel rail retaining clip (if equipped). Remove injectors from fuel rail. Remove injector "O" rings and discard.

To install, reverse removal procedure. Coat NEW injector "O" rings with clean engine oil. Install injector-to-fuel rail retaining clip with open end facing injector electrical connection. Position fuel rail on intake manifold. Push down on rail to seat injectors in manifold. Tighten fuel rail retaining bolts. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

Scheme 13

Scheme 14

IDLE AIR CONTROL (IAC) VALVE

Remove electrical connector from IAC valve. Remove IAC valve, gasket and "O" ring from throttle body assembly.

1. Inspect gasket or "O" ring for damage. Replace as necessary. Check the extended distance of IAC pintle before installing. Damage will occur if measurement is incorrect. Distance must not exceed 1.100" (28 mm). Measurement should be taken from valve housing flange to end of pintle cone.
2. To retract NEW IAC valve pintle, slowly exert finger pressure on valve. Install NEW "O" ring or gasket on valve. Coat "O" ring with clean engine oil. Install IAC valve. Tighten IAC valve to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/camaro/iv-1992-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-38l) . Install electrical connector. To reset IAC valve, refer to ADJUSTMENTS article.

IN-LINE FUEL FILTER

1. Remove negative battery cable.
2. Relieve fuel system pressure. Refer to «FUEL PRESSURE RELIEF»(/chevrolet/camaro/iv-1992-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-38l__fuel-pressure-relief) .
3. Raise vehicle.
4. Clean all in-line fuel filter connections and surrounding areas before disconnecting to avoid possible contamination of the fuel system.
5. Remove quick-connect fitting at fuel filter inlet.
6. Remove threaded fitting from fuel filter outlet.
7. Slide fuel filter from bracket.
8. Inspect fuel pipe O-ring for cuts, nicks, swelling or distortion. Replace as necessary.

1. Slide fuel filter into bracket.
2. Install threaded fitting to fuel filter outlet. Tighten in-line fuel filter fitting to 22 Ft. lbs. (30 N.m).
3. Install quick-connect fitting to fuel filter inlet.
4. Lower vehicle.
5. Tighten fuel filter cap.
6. Install negative battery cable.
7. Turn ignition ON for 2 seconds and then OFF for 10 seconds. Turn ON and check for fuel leaks.

1. Relieve fuel system pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/camaro/iv-1992-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-38l__fuel-pressure-relief) . Disconnect battery negative terminal. Raise car on hoist. Drain fuel from fuel tank. Disconnect exhaust pipe at converter and rear hanger. Allow exhaust to hang over axle assembly.
2. Remove tailpipe and muffler heat shields. Remove fuel filler neck shield behind left rear tire. Remove rear suspension track bar and brace. Disconnect harness connector to fuel pump assembly.
3. Disconnect all fuel lines. Remove fuel line retaining bracket on left side and remove brake line clip from bracket.
4. Position support jack under axle assembly. Disconnect lower ends of shock absorbers. Disconnect rear stabilizer bar from frame (if equipped).
5. On models equipped with 2-piece driveshaft, remove center support bearing-to-rear axle torque arm bolts. On all models, remove rear axle torque arm-to-differential housing bolts/nuts. Wire end of rear axle torque arm aside. Remove driveshaft-to-differential yoke bolts/screws. Wire end of driveshaft aside.
6. Lower rear suspension as far as possible without damaging brake lines and cables and remove both coil springs. Remove tank straps bolts. Remove fuel tank by rotating front of tank down and sliding to the right. Remove fuel pump assembly from fuel tank.
7. To install, reverse removal procedure using new "O" ring/gasket. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/camaro/iv-1992-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-38l__torque-specifications) .

Turn ignition switch to OFF position. Disconnect electrical connector from TP sensor. Remove TP sensor retaining screws. Remove TP sensor from throttle body.

With throttle valve in closed position, install TP sensor on throttle body. Ensure TP sensor lever engages with drive lever on throttle shaft. Install retaining screws and electrical connection. TP sensor is self-zeroing and is not adjustable.

OXYGEN SENSOR

Oxygen sensor is mounted in exhaust pipe, below exhaust manifold. It is equipped with a permanent pigtail which must remain intact when removing sensor.

1. Ensure sensor is free of contaminants. DO NOT use cleaning solvents of any type. Sensor may be difficult to remove when engine temperature is less than 120°F (48°C). Excessive removal force may damage threads in exhaust manifold or pipe.
2. Disconnect negative battery cable. Disconnect electrical connector from oxygen sensor. Carefully remove oxygen sensor from exhaust pipe.

1. Whenever an oxygen sensor is removed, coat threads with anti-seize compound before it is reinstalled. New oxygen sensors already have this compound applied to threads.
2. Install oxygen sensor in exhaust pipe. Tighten sensor to 30 ft. lbs. (41 N.m). Reconnect electrical connector to oxygen sensor. Reconnect negative battery cable.

SUPERCHARGER

Note. Servicing of supercharger unit is limited to replacement only.

Removal (VIN 1)

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/camaro/iv-1992-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-38l__fuel-pressure-relief) . Disconnect negative battery cable. Remove accessory drive belt from supercharger pulley.
2. Remove fuel injector sight shield. Disconnect fuel lines from fuel rail. Disconnect vacuum hoses. Disconnect injector electrical connectors. Disconnect electrical from front of supercharger. Remove fuel rail bolts. Remove fuel rail and injectors as an assembly. See «FUEL RAIL & INJECTORS»(/chevrolet/camaro/iv-1992-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-38l__fuel-rail-injectors) .
3. Disconnect electrical connectors from IAC valve, TP sensor, MAP sensor, MAF sensor, EGR valve, boost control solenoid, and engine coolant temperature sensor. Remove air intake duct from throttle body. Remove EGR pipe from supercharger. Disconnect throttle and cruise control cables. Remove boost pressure manifold and vacuum block. Remove cable bracket and tensioner bracket to supercharger mounting stud. NOTE: Tensioner bracket-to-supercharger stud must be removed, or supercharger cannot be lifted high enough to clear lower intake manifold locator pins.
4. Remove throttle body from supercharger. Remove supercharger-to-intake manifold bolts, supercharger gasket and coolant passage "O" rings.

Ensure locator pins are in their proper location on intake manifold. Replace gaskets and "O" rings. DO NOT use any type of sealant on gasket. To complete installation, reverse removal procedure. Tighten supercharger-to-intake manifold bolts to 19 ft. lbs. (26 N.m). Tighten fuel rail retaining bolts to 97 INCH lbs. (11 N.m).

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• POWERTRAIN CONTROL MODULE (PCM)
• TORQUE SPECIFICATIONS
• FUEL PRESSURE RELIEF
• IDLE AIR
• TORQUE SPECIFICATIONS
• FUEL RAIL & INJECTORS