Engine Controls and Fuel - 6.2l, or 7.0l - Introduction Chevrolet Corvette C6

Temperature Versus Resistance

Altitude Versus Barometric Pressure

Ignition System Specifications

Fastener Tightening Specifications

Scheme 1

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Diagnostic Starting Point - Engine Controls

Begin the system diagnosis with Diagnostic System Check - Vehicle . The Diagnostic System Check - Vehicle will provide the following information

1. The identification of the control modules which command the system
2. The ability of the control modules to communicate through the serial data circuit
3. The identification of any stored diagnostic trouble codes (DTCs) and the codes' statuses

The use of the Diagnostic System Check - Vehicle will identify the correct procedure for diagnosing the system and where the procedure is located.

DIAGNOSTIC CODE INDEX

DIAGNOSTIC CODE INDEX

Engine Control Module Replacement

Engine control module (ECM) service should normally consist of either ECM replacement or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures require ECM replacement, check the ECM first to see if the correct part is being used.

Note. In order to prevent internal ECM damage, the ignition must be OFF when you disconnect or reconnect the power to the ECM. For example, disconnect the power when you work with the following components

1. A battery cable
2. The ECM pigtail
3. The ECM fuse
4. The jumper cables

Note. When you diagnose or replace the ECM, remove any debris from the ECM connector surfaces before servicing the ECM module connector gaskets. Ensure that the gaskets are installed correctly. The gaskets prevent intrusion into the ECM. The replacement ECM MUST be programmed.

Removal Procedure

1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life.
2. Remove the wheelhouse filler panel. Refer to «Front Wheelhouse Liner Replacement (Front Liner)»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Front Wheelhouse Liner Replacement (Rear Liner)»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
3. Remove the ECM bolts (1).
4. Remove the ECM from the bracket and allow the ECM to hang down from the engine wiring harness.
5. Disconnect the engine wiring harness electrical connectors (1) from the ECM.
6. Remove the ECM.

Installation Procedure

1. Position the ECM.
2. Connect the engine wiring harness electrical connectors (1) to the ECM and position the ECM into the bracket.
3. Install the ECM bolts (1) and tighten to 10 N.m (89 lb in).
4. Install the wheelhouse filler panel. Refer to «Front Wheelhouse Liner Replacement (Front Liner)»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Front Wheelhouse Liner Replacement (Rear Liner)»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
5. If a new ECM is being installed, program the ECM. Refer to «Control Module References»(/chevrolet/corvette/c6-2004-2014/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) .

Crankshaft Position System Variation Learn

1. Install a scan tool.
2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/oem-general-information/#vehicle-diagnostic-information__diagnostic-trouble-code-dtc-list) for the applicable DTC that set.
3. Select the crankshaft position (CKP) variation learn procedure with a scan tool.
4. 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 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: CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature.
5. Enable the CKP System Variation Learn Procedure with a scan tool.
6. Accelerate to WOT.
7. Release when the fuel cut-off occurs.
8. Test in progress.
9. 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/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-dtc-p0153-to-dtc-p0507) . If any other DTCs set, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/oem-general-information/#vehicle-diagnostic-information__diagnostic-trouble-code-dtc-list) for the applicable DTC that set.
10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully.
11. The CKP Variation Learn Procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: A CKP sensor replacement An engine replacement A ECM replacement A harmonic balancer replacement A crankshaft replacement Any engine repairs which disturb the CKP sensor relationship

Description

The engine control module (ECM) learns the airflow through the throttle body to ensure the correct idle. The learned airflow values are stored within the ECM. These values are learned to adjust for production variation and will continuously learn during the life of the vehicle to compensate for reduced airflow due to coking. Anytime the throttle body airflow rate changes, for example due to cleaning or replacing, the values must be relearned.

A vehicle that had a heavily coked throttle body that has been cleaned or replaced may take several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability to reset all learned values back to zero. A new ECM will also have values set to zero.

The idle may be unstable or a DTC may set if the learned values do not match the actual airflow.

With Scan Tool - Reset Procedure

1. DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120, P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205, P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606, P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128, P2135, P2138, or P2176 are not set.
2. Ignition ON, engine OFF.
3. The vehicle speed sensor (VSS) is 0 km/h (0 mph).

Without Scan Tool - Learn Procedure

1. DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120, P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205, P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606, P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128, P2135, P2138, or P2176 are not set.
2. The engine speed is between 450-4,000 RPM.
3. The manifold absolute pressure (MAP) is greater than 5 kPa.
4. The mass air flow (MAF) is greater than 2 g/s.
5. The ignition 1 voltage is greater than 10 volts.

1. Ignition ON, engine OFF, with a scan tool, perform the Idle Learn Reset in Module Setup.
2. Start the engine, monitor the TB Idle Airflow Compensation parameter. The TB Idle Airflow Compensation value should equal 0 percent and the engine should be idling at a normal idle speed.
3. Clear the DTCs and return to the diagnostic that referred you here.

1. Start and idle the engine in PARK for 3 minutes.
2. With a scan tool, monitor desired and actual RPM.
3. The ECM will start to learn the new idle cells and Desired RPM should start to decrease.
4. Ignition OFF for 60 seconds.
5. Start and idle the engine in PARK for 3 minutes.
6. After the 3 minute run time the engine should be idling normal. IMPORTANT: During the drive cycle the check engine light may come on with idle speed DTCs. If idle speed codes are set, clear codes so the ECM can continue to learn. If the engine idle speed has not been learned the vehicle will need to be driven at speeds above 70 km/h (44 mph) with several decelerations and extended idles.
7. After the drive cycle, the engine should be idling normally. If the engine idle speed has not been learned, turn OFF the ignition for 60 seconds and repeat step 6.
8. Once the engine speed has returned to normal, clear DTCs and return to the diagnostic that referred you here.

1. Turn OFF the ignition.
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
3. Drain the engine coolant below the level of the engine coolant temperature (ECT) sensor. Refer to «Cooling System Draining and Filling (Static Fill)»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (GE 47716)»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Lower the vehicle.
5. Disconnect the harness connector from the ECT sensor.
6. Remove the ECT sensor.

1. Coat the ECT sensor threads with sealer P/N 12346004 (Canadian P/N 10953480) or the equivalent.
2. Install the ECT sensor. Tighten: Tighten the ECT sensor to 20 N.m (15 lb ft).
3. Connect the ECT sensor electrical connector.
4. Refill the engine coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (GE 47716)»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) .

Scheme 41

1. Disconnect the mass air flow (MAF)/air intake temperature (IAT) sensor electrical connector.
2. Remove the 2 screws and the MAF/IAT sensor from the air cleaner housing.

1. Install the MAF/IAT sensor and the 2 screws to in the air cleaner housing.
2. Connect the MAF/IAT sensor electrical connector.

Scheme 42

1. Remove the oil filler cap (1).
2. Remove the right engine sight shield (2).
3. Remove the manifold absolute pressure (MAP) sensor (4).
4. Disconnect the electrical connector (3) for the MAP sensor.

1. Reconnect the MAP sensor electrical connector (3) to the engine wiring harness.
2. Install the MAP sensor (4).
3. Install engine sight shield (2).
4. Install the oil filler cap (1).

Scheme 43

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
2. Disconnect the bank 1, oxygen sensor 1 (1) electrical connector, from the engine wiring harness electrical connector.
3. Remove the bank 1, oxygen sensor 1 (1) from the exhaust manifold.

Note. Use special anti-seize compound on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite burns away, but the glass beads remain, making the sensor easier to remove. New or service sensors already have the compound applied to the threads. If you remove an oxygen sensor and if for any reason you must reinstall the same oxygen sensor, apply the anti-seize compound to the threads before reinstallation.

1. Coat the threads of the heated oxygen sensor with the anti-seize compound P/N 5613695, or the equivalent if necessary.
2. Install the heated oxygen sensor (1). Tighten: Tighten the HO2S to 41 N.m (30 lb ft).
3. Reconnect the bank 1, oxygen sensor (4), electrical connector to the engine wiring harness electrical connector.
4. Lower the vehicle.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
2. Disconnect the bank 1, oxygen sensor 2 (2), electrical connector from the engine harness.
3. Remove the bank 1, oxygen sensor 2 (2), in the catalytic convertor.

Note. Use special anti-seize compound on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite burns away, but the glass beads remain, making the sensor easier to remove. New or service sensors already have the compound applied to the threads. If you remove an oxygen sensor and if for any reason you must reinstall the same oxygen sensor, apply the anti-seize compound to the threads before reinstallation.

1. Coat the threads of the heated oxygen sensor with the anti-seize compound P/N 5613695, or the equivalent if necessary.
2. Install the bank 1, oxygen sensor 2 (2), in the catalytic convertor. Tighten: Tighten the oxygen sensor to 41 N.m (30 lb ft).
3. Reconnect the bank 1, oxygen sensor 2 (2), electrical connector to the engine wiring harness electrical connector.
4. Lower the vehicle.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
2. Disconnect bank 2, oxygen sensor 1 (3), electrical connector from the engine harness electrical connector.
3. Remove the bank 2, oxygen sensor 1 (3), from the catalytic convertor.

Note. Use special anti-seize compound on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite burns away, but the glass beads remain, making the sensor easier to remove. New or service sensors already have the compound applied to the threads. If you remove an oxygen sensor and if for any reason you must reinstall the same oxygen sensor, apply the anti-seize compound to the threads before reinstallation.

1. Coat the threads of the bank 2, oxygen sensor 1 (3) with the anti-seize compound P/N 5613695, or the equivalent if necessary.
2. Install the bank 2, oxygen sensor 1 (3), in the exhaust manifold. Tighten: Tighten the oxygen sensor to 41 N.m (30 lb ft).
3. Reconnect the bank 2, oxygen sensor 1 (3), electrical connector to the engine wiring harness electrical connector.
4. Lower the vehicle.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
2. Disconnect the bank 2, oxygen sensor 2 (4), electrical connector from the engine wiring harness connector.
3. Remove the bank 2, oxygen sensor 2 (4), from the catalytic converter.

Note. Use special anti-seize compound on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite burns away, but the glass beads remain, making the sensor easier to remove. New or service sensors already have the compound applied to the threads. If you remove an oxygen sensor and if for any reason you must reinstall the same oxygen sensor, apply the anti-seize compound to the threads before reinstallation.

1. Coat the threads of the oxygen sensor 2 with the anti-seize compound P/N 5613695, or the equivalent if necessary.
2. Install the bank 2, oxygen sensor 2 (4), in the catalytic converter. Tighten: Tighten the bank 2, oxygen sensor 2 to 41 N.m (30 lb ft).
3. Reconnect the bank 2, oxygen sensor 2 (4), electrical connector to the engine wiring harness electrical connector.
4. Lower the vehicle.

1. Remove the left instrument panel (I/P) on the lower closeout insulator panel. Refer to «Instrument Panel Insulator Panel Replacement»(/chevrolet/corvette/c6-2004-2014/remont/gauges-instrument-panels/#instrument-panel-trim-and-console-trim) .
2. Disconnect the electrical connector of the accelerator pedal sensor module.
3. Remove the accelerator pedal mounting bolts.
4. Remove the accelerator pedal.

1. Install the accelerator pedal to the steering column support bracket.
2. Install the accelerator pedal mounting bolts. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
3. Connect the accelerator pedal sensor module electrical connector.
4. Inspect for correct carpet fit under the accelerator pedal.
5. Install the left I/P on the lower closeout insulator panel. Refer to «Instrument Panel Insulator Panel Replacement»(/chevrolet/corvette/c6-2004-2014/remont/gauges-instrument-panels/#instrument-panel-trim-and-console-trim) .

1. An 8-digit part identification number is stamped on the throttle body casting. Refer to this number if servicing, or if a part replacement is required.
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement (6.2L)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) or «Air Cleaner Assembly Replacement (7.0L)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) or «Air Cleaner Assembly Replacement (LS9)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
3. Disconnect the air control valve electrical connector.
4. Remove the 4 throttle body bolts.
5. Remove the throttle body and the gasket. NOTE: Do not reuse the throttle body gasket. Install a new gasket during assembly.
6. Discard the throttle body gasket.

1. Install a new throttle body gasket.
2. Install the throttle body assembly.
3. Install the 4 throttle body bolts and tighten to 10 N.m (89 lb in).
4. Connect the air control valve electrical connector.
5. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement (6.2L)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) or «Air Cleaner Assembly Replacement (7.0L)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) or «Air Cleaner Assembly Replacement (LS9)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
6. Perform the throttle learn procedure. Refer to «Throttle Learn»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .

Scheme 44

Throttle Body Cleaning

1. Remove the air intake duct.
2. Inspect the throttle body bore and the throttle valve plate for deposits. If necessary, open the throttle valve to inspect all surfaces.
3. Clean the throttle body bore and the throttle valve plate using a clean shop towel with an appropriate cleaning substance, such one of the following: GM Top Engine Cleaner P/N 1052626 ACDelco Carburetor Tune-Up Conditioner P/N X66-P
4. Install the air intake duct.
5. Perform the throttle learn procedure. Refer to «Throttle Learn»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .

Special Tools

CH-48027 Digital Pressure Gage. See Special Tools .

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Without CH 48027)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction__fuel-pressure-relief-without-ch-48027) or «Fuel Pressure Relief (With CH 48027)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
2. Connect the CH-48027-1 (1) to the CH-48027-2 (2).
3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's directions. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .

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

Fuel Pressure Relief (Without CH 48027)

1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to «Electrical Center Identification Views»(/chevrolet/corvette/c6-2004-2014/remont/electrical-component-locations/#wiring-systems-and-power-management-electrical-center-id-and-component-and-splice-pack-connector-end-views) .
2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure.
3. Remove the engine cover, if required.
4. Remove the fuel rail service port cap.
5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve.
6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
7. Install the fuel rail service port cap.
8. Install the engine cover, if required.
9. Tighten the fuel fill cap.

CH-48027 Digital Pressure Gage. See Special Tools .

Fuel Pressure Relief Procedure

1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to «Electrical Center Identification Views»(/chevrolet/corvette/c6-2004-2014/remont/electrical-component-locations/#wiring-systems-and-power-management-electrical-center-id-and-component-and-splice-pack-connector-end-views) .
2. Remove the engine cover, if required.
3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure.
4. Remove the fuel rail service port cap.
5. Wrap a shop towel around the fuel rail service port.
6. Connect the CH-48027-3 (4) to the fuel rail service port.
7. Connect the CH-48027-2 (2) to the CH-48027-3 (4).
8. Place the hose on the CH-48027-2 (2) into an approved gasoline container.
9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2).
11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container.
12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
13. Disconnect the CH-48027-3 (4) from the fuel rail service port.
14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
15. Install the fuel rail service port cap.
16. Install the engine cover, if required.
17. Tighten the fuel fill cap.

J 37088-A Fuel Line Disconnect Tool Set

1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the «Fuel Pressure Relief (Without CH 48027)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction__fuel-pressure-relief-without-ch-48027) or «Fuel Pressure Relief (With CH 48027)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
2. Slide the dust cover from the quick connect fitting.
3. Blow any dirt out of the fitting, using compressed air.
4. Choose the correct tool from the J 37088-A Tool Set for the size of the fitting. Insert the tool into the female connector, then push inward in order to release the locking tabs.
5. Pull the connection apart.
6. Using a clean shop towel, wipe off the male pipe end.
7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required.

1. Apply a few drops of clean engine oil to the male pipe end.
2. Push both sides of the fitting together in order to cause the retaining tabs to snap into place.
3. Once installed, pull on both sides of the fitting in order to make sure the connection is secure.
4. Reposition the dust cover over the quick connect fitting.

J 37088-A Fuel Line Disconnect Tool Set

1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the «Fuel Pressure Relief (Without CH 48027)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction__fuel-pressure-relief-without-ch-48027) or «Fuel Pressure Relief (With CH 48027)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
2. Using compressed air, blow any dirt out of the quick-connect fitting.
3. Squeeze the plastic retainer release tabs.
4. Choose the correct tool from the J 37088-A Tool Set for the size of the fitting. Insert the tool into the female connector, then push inward in order to release the locking tabs. The plastic retainer will remain on the female connector.
5. Pull the connection apart.

1. Apply a few drops of clean engine oil to the male fuel pipe end.
2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs/fingers to snap into place.
3. Once installed, pull on both sides of the quick-connect fitting in order to make sure the connection is secure.

Scheme 45

Scheme 46

J 45004 Fuel Tank Drain Hose. See Special Tools .

Draining Procedure

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Without CH 48027)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction__fuel-pressure-relief-without-ch-48027) or «Fuel Pressure Relief (With CH 48027)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
2. Remove the fuel tank filler pipe cap.
3. Drain the fuel through the fuel tank filler pipe using a hand or air operated fuel pump device and the J 45004 . See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
4. Remove the driveline support assembly. Refer to «Driveline Support Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/driveshaft-universal-joints/#propeller-shaft) .
5. Remove the crossover tube/hose from the RH fuel tank.
6. Drain the fuel through the fuel tank crossover connection using a hand or air operated fuel pump device and the J 45004 . See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .

1. Remove the fuel filler cap.
2. Remove the left rear wheelhouse panel. Refer to «Rear Wheelhouse Panel Liner Replacement»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
3. Disconnect the fuel fill hose (1) and the vent hose (2) from the fuel tank fill and vent pipe.
4. Cap the open ends of the fuel fill hose (1) and the vent hose (2).
5. Disconnect the fuel system ground strap.
6. Remove the fuel tank fill and vent pipe from the fuel filler pocket.

1. Install the fuel tank fill and vent pipe to the fuel filler pocket. Tighten: Tighten the fuel tank fill and vent pipe bolts to 3.0 N.m (22 lb in).
2. Connect the fuel fill pipe ground strap. Tighten: Tighten the fuel fill pipe ground strap bolt to 8 N.m (71 lb in).
3. Uncap the openings on the fuel fill hose (1) and the vent hose (2).
4. Connect the fuel fill hose (1) and the vent hose (2) to the fuel tank fill and vent pipe. Tighten: Tighten the fuel fill hose clamp to 4 N.m (35 lb in).
5. Install the left rear wheelhouse panel. Refer to «Rear Wheelhouse Panel Liner Replacement»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
6. Install the fuel filler cap.

1. Remove the left fuel tank. Refer to «Fuel Level Sensor Replacement - Left Side»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
2. Remove the fuel fill hose (1) from the fuel tank.
3. Cap the open end of the fuel tank.

1. Uncap the opening on the fuel tank.
2. Install the fuel fill hose (1) to the fuel tank. Tighten: Tighten the fuel fill hose clamp to 4 N.m (35 lb in).
3. Install the left fuel tank. Refer to «Fuel Level Sensor Replacement - Left Side»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .

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

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
2. Drain the fuel tank. Refer to «Fuel Tank Draining»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
3. Remove the left rear wheelhouse panel. Refer to «Rear Wheelhouse Panel Liner Replacement»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
4. Remove both mufflers. Refer to «Exhaust Muffler Replacement - Left Side»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) and «Exhaust Muffler Replacement - Right Side»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) .
5. If automatic transmission, remove the driveline support assembly. Refer to «Driveline Support Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/driveshaft-universal-joints/#propeller-shaft) .
6. Disconnect the fuel fill hose and recirc line from the fill pipe.
7. Disconnect the fuel pump jumper harness connector.
8. Disconnect the fuel feed pipe (4) at the rear of the left fuel tank. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
9. Cap the fuel pipes to prevent fuel system contamination.
10. Loosen the fuel tank strap in order to drop the tank approximately 1 inch.
11. Disengage the crossover tube connector position assurance (CPA) retainer by pulling the tab (1) outward and rotate.
12. Rotate the collar counterclockwise to disengage.
13. Disconnect the crossover tube (5) from the left fuel tank.
14. Disconnect the evaporative emission (EVAP) crossover pipe (2) quick connect fitting at the left fuel tank.
15. Cap the EVAP pipes (1 and 3) to prevent system contamination.
16. Remove the fuel tank strap mount bolts.
17. Remove the fuel tank strap from the vehicle.
18. Remove the fuel tank.
19. If the fuel pump sending unit is being removed and installed into the new tank, refer to «Fuel Tank Fuel Pump Module Replacement - Left Side (LS3, LS7)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) or «Fuel Tank Fuel Pump Module Replacement - Left Side (LS9)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction)

1. If replacing the tank with LS9 engine, install a NEW heat shield (1) to the left side tank by removing the backing from the adhesive.
2. Press firmly to ensure full contact and adhesion onto the tank.
3. Install the fuel tank.
4. Install the fuel tank strap to the vehicle.
5. Install the fuel tank strap bolts loosely leaving the tank hanging approximately one inch.
6. Remove the caps from the EVAP pipes (1 and 3).
7. Connect the EVAP crossover pipe (2) quick connect fitting at the left fuel tank.
8. Lubricate the crossover tube to fuel tank connection O-rings (1-4) with GM P/N 1051717 (Canadian P/N 5728223) rubber lubricant.
9. Lubricate the crossover tube O-ring mating surfaces (1-4) with GM P/N 1051717 (Canadian P/N 5728223) rubber lubricant.
10. Connect the crossover tube to the left fuel tank using the features previously noted.
11. Rotate the crossover tube collar (3) clockwise to engage the tangs.
12. Rotate the crossover tube CPA retainer counterclockwise past the collar latching tang and push the tab (1) into the locked position.
13. Test the crossover tube to fuel tank connection by attempting to rotate the crossover tube collar counterclockwise.
14. Tighten the fuel tank strap bolts. Tighten: Tighten the bolts to 25 N.m (18 lb in).
15. Remove the cap from the fuel pipes.
16. Connect the fuel feed pipe (4) at the rear of the left fuel tank. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
17. Connect the fuel pump jumper harness connector.
18. Connect the fuel fill hose and recirc line to the fill tube. Tighten: Tighten the clamp to 4 N.m (35 lb in).
19. If automatic transmission, install the driveline support assembly. Refer to «Driveline Support Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/driveshaft-universal-joints/#propeller-shaft) .
20. Install both mufflers. Refer to «Exhaust Muffler Replacement - Left Side»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) and «Exhaust Muffler Replacement - Right Side»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) .
21. Install the left rear wheelhouse panel. Refer to «Rear Wheelhouse Panel Liner Replacement»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
22. Lower the vehicle.
23. Refuel the fuel tank.
24. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
25. Perform the following procedure in order to test for leaks: Turn ON the ignition switch for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks. Specification: Fuel pump on: 400 kPa (58 psi) Fuel pump off: 359 kPa (52 psi)

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

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
2. Drain the fuel tank. Refer to «Fuel Tank Draining»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
3. Remove the right rear wheelhouse panel. Refer to «Rear Wheelhouse Panel Liner Replacement»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
4. If automatic transmission, remove the driveline support assembly. Refer to «Driveline Support Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/driveshaft-universal-joints/#propeller-shaft) .
5. Remove the evaporative emission (EVAP) canister access cover.
6. Disconnect the fill limit vent valve (FLVV) hose (1) at the EVAP canister (2).
7. Disconnect the fuel pump module harness connector.
8. Remove the crossover tube from the clamp located above the transmission.
9. Disengage the crossover tube connector position assurance (CPA) retainer by pulling the tab (1) outward and rotate.
10. Rotate crossover tube collar counterclockwise to disengage.
11. Disconnect the crossover tube (5) from the right fuel tank by pulling the tube straight out of the fuel tank connection.
12. Disconnect the EVAP crossover pipe (2) quick connect fitting at the right fuel tank.
13. Cap the EVAP pipe to prevent system contamination.
14. Remove the fuel tank strap mount bolts.
15. Remove the fuel tank strap from the vehicle.
16. Remove the fuel tank.

1. If replacing the tank with LS9 engine, install a NEW heat shield (1) to the right side tank by removing the backing from the adhesive.
2. Press firmly to ensure full contact and adhesion onto the tank.
3. Install the fuel tank.
4. Install the fuel tank strap to the vehicle.
5. Install the fuel tank strap bolts.
6. Remove the cap from the EVAP pipe.
7. Connect the EVAP crossover pipe (2) quick connect fitting at the right fuel tank.
8. Inspect the O-rings for damage. Lubricate the crossover tube to fuel tank connection O-rings (1-4) with GM P/N 1051717 (Canadian P/N 5728223) rubber lubricant.
9. Lubricate the crossover tube O-ring mating surfaces (1-4) with GM P/N 1051717 (Canadian P/N 5728223) rubber lubricant.
10. Connect the crossover tube to the right fuel tank using the features previously noted.
11. Rotate the crossover tube collar (3) clockwise to engage the tangs.
12. Rotate the crossover tube CPA retainer counterclockwise past the collar latching tang and push the tab (1) into the locked position.
13. Test the crossover tube to fuel tank connection by attempting to rotate the crossover tube collar counterclockwise.
14. Tighten the fuel tank strap bolts. Tighten: Tighten the bolts to 25 N.m (18 lb in).
15. Snap the crossover tube into the clamp located above the transmission.
16. Connect the fuel pump module harness connector.
17. Connect the FLVV hose (1) at the EVAP canister (2).
18. Install the EVAP canister access cover.
19. If automatic transmission, install the driveline support assembly. Refer to «Driveline Support Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/driveshaft-universal-joints/#propeller-shaft) .
20. Install the right rear wheelhouse panel. Refer to «Rear Wheelhouse Panel Liner Replacement»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
21. Lower the vehicle.
22. Refuel the fuel tank.
23. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
24. Perform the following procedure in order to test for leaks: Turn ON the ignition switch for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks. Specification: Fuel pump on: 400 kPa (58 psi) Fuel pump off: 359 kPa (52 psi)
25. Program the transmitters. Refer to «Transmitter Programming (N. America and Japan, except Canada)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-n-america-and-japan) or «Transmitter Programming (Canada and Europe)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-canada-and-europe) or «Transmitter Programming (New RCDLR ONLY)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-new-rcdlr-only) .

1. Remove the driveline support assembly. Refer to «Driveline Support Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/driveshaft-universal-joints/#propeller-shaft) .
2. Remove the crossover tube from the clamp located above the transmission.
3. Disengage the left crossover tube connector position assurance (CPA) retainer by pulling the tab (1) outward and rotate.
4. Rotate crossover tube collar counterclockwise to disengage.
5. Disconnect the crossover tube from the left fuel tank by pulling the tube straight out of the fuel tank connection.
6. Repeat steps 3-5 for the right side tank.

1. Inspect the O-rings for damage. Lubricate the right crossover tube to fuel tank connection O-rings (1-4) with GM P/N 1051717 (Canadian P/N 5728223) rubber lubricant.
2. Lubricate the crossover tube O-ring mating surfaces (1-4) with GM P/N 1051717 (Canadian P/N 5728223) rubber lubricant.
3. Connect the crossover tube to the right fuel tank using the features previously noted.
4. Rotate the crossover tube collar (3) clockwise to engage the tangs.
5. Rotate the crossover tube CPA retainer counterclockwise past the collar latching tang and push the tab (1) into the locked position.
6. Test the crossover tube to fuel tank connection by attempting to rotate the crossover tube collar counterclockwise.
7. Repeat steps 1-6 for the left side fuel tank.
8. Snap the crossover tube into the clamp located above the transmission.
9. Install the driveline support assembly. Refer to «Driveline Support Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/driveshaft-universal-joints/#propeller-shaft) .

1. Remove the right rear wheelhouse panel. Refer to «Rear Wheelhouse Panel Liner Replacement»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
2. Remove the evaporative emission (EVAP) canister access cover.
3. Disconnect the fuel tank pressure sensor electrical connector.
4. Remove the fuel tank pressure sensor by carefully prying the sensor out of the fuel tank with a screwdriver.

1. Lubricate the fuel tank pressure sensor rubber grommet with clean engine oil in order to aid in installation.
2. Install the fuel tank pressure sensor into the top of the fuel tank.
3. Connect the fuel tank pressure sensor electrical connector.
4. Install the EVAP canister access cover.
5. Install the right rear wheelhouse panel. Refer to «Rear Wheelhouse Panel Liner Replacement»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .

J39765-A Fuel Sender Lock Ring Tool. See Special Tools .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
2. Remove the left fuel tank. Refer to «Fuel Tank Replacement - Left Side»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
3. Place the fuel tank on a suitable work surface.
4. Disconnect the fuel pump jumper harness from the fuel pump module (1).
5. Disconnect the jet line insert connector from the crossover tube to fuel tank opening.
6. Disconnect the fuel feed line from the welded clip on the side of the fuel tank.
7. Using the J39765-A , remove the fuel pump module locking ring. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
8. Carefully remove the fuel pump module from the fuel tank, with the jet lines connected. Take care not to damage the fuel sender float arm.
9. Disconnect the jet line quick-connect connectors from the fuel pump module inner port.
10. Remove the jet line from the module retainer cup. This line has no attached connector.
11. Remove the fuel pump module O-ring from the fuel tank opening.
12. Remove the jet line insert through the crossover tube to fuel tank opening.

1. Inspect the jet line insert for damage and replace if necessary.
2. Install the jet line insert through the crossover tube to fuel tank opening.
3. Install a new fuel pump module O-ring to the fuel tank opening.
4. Place tape around the jet line with the connector. This will permit line access once the pump module is inserted into the fuel tank.
5. Install the pump module into the fuel tank half way, taking care not to damage the float arm.
6. Using the tape as a guide, gently pull the jet line up through the fuel pump module opening.
7. Place the jet line with no connector in the module retainer cup.
8. Secure the line into the module retaining clip.
9. Remove the tape from the jet line with a connector.
10. Connect the jet line quick-connect connectors to the fuel pump module inner port.
11. Compress and align the fuel pump module into the fuel tank, while taking care not to damage the float arm.
12. Install the fuel pump module lock ring.
13. Using the J39765-A , fully lock the fuel pump module lock ring in place. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
14. Connect the fuel supply line into the weld clip on the side of the fuel tank.
15. Using a DMM, verify the full and empty readings resistance reading of the fuel pump module. Turn the fuel tank upside down to achieve the full tank reading. Resistance: Empty tank reading 247-253 ohms resistance Full tank reading 38.5-41.05 ohms resistance
16. Connect the jet line insert connector into the crossover tube to fuel tank opening.
17. Connect the fuel pump jumper harness to the fuel pump module (1).
18. Install the left fuel tank. Refer to «Fuel Tank Replacement - Left Side»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
19. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .

J-39765-A: Fuel Sender Lock Ring Tool

1. Remove the left fuel tank. Refer to «Fuel Tank Replacement - Left Side»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
2. Disconnect the jet line insert connector (1) from the crossover tube to fuel tank opening.
3. Disconnect the fuel feed line (2) from the welded clip on the side of the fuel tank.
4. Using the J-39765-A: ring, turn the fuel pump module locking ring (1) counterclockwise.
5. Partially raise the fuel pump module from the fuel tank, and disconnect the fuel supply line (1) refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
6. Reach into the tank and remove the fuel return line (1).
7. Remove the fuel tank module (1) and O-ring (2).

1. Inspect the jet line insert for damage and replace if necessary.
2. Install a new fuel pump module O-ring to the fuel tank opening.
3. Loop string around the fuel supply line (1) and the fuel return line (2) and lower them into the tank.
4. With the aid of an assistant, partially lower the fuel sender assembly into the tank and connect the fuel supply line (1).
5. Remove the looped string from the supply line.
6. With the aid of an assistant, use a Snap-on soft grip trim tool ASG187B or equivalent in order to insert the return line (1) into the module retainer cup.
7. Remove the looped string from the return line.
8. Compress and align the fuel pump module into the fuel tank.
9. Install the fuel pump module lock ring.
10. Using the J-39765-A: ring, fully lock the fuel pump module lock ring in place by rotating clockwise.
11. Connect the fuel feed line (2) to the welded clip on the side of the fuel tank.
12. Connect the jet line insert connector (1) to the crossover tube fuel tank opening.
13. Using a DMM, verify the full and empty readings resistance reading of the fuel pump module. Turn the fuel tank upside down to achieve the full tank reading. Resistance: Empty tank reading 247-253 ohms resistance Full tank reading 38.5-41.05 ohms resistance
14. Install the left fuel tank. Refer to «Fuel Tank Replacement - Left Side»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .

J39765-A Fuel Sender Lock Ring Tool. See Special Tools .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
2. Remove the right fuel tank. Refer to «Fuel Tank Replacement - Right Side»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
3. Place the fuel tank on a suitable work surface.
4. Disconnect the evaporative emission (EVAP) purge line (4) from the fuel pump module.
5. Disconnect the fuel pump module harness connector (5).
6. Disconnect the fuel tank pressure (FTP) sensor harness connector (1).
7. If replacing the fuel pump module, remove the FTP sensor (2). Refer to «Fuel Tank Pressure Sensor Replacement»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
8. Disconnect the jet line insert connector from the crossover tube to fuel tank opening.
9. Using the J39765-A , remove the fuel pump module locking ring. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
10. Carefully remove the fuel pump module from the fuel tank, with the jet lines connected. Take care not to damage the fuel sender float arm.
11. Disconnect the jet line quick-connect connectors from the fuel pump module, noting the location of the lines for installation.
12. Remove the fuel pump module O-ring from the fuel tank opening.
13. Remove the jet line insert through the crossover tube to fuel tank opening.

1. Inspect the jet line insert for damage and replace if necessary.
2. Install the jet line insert through the crossover tube to fuel tank opening.
3. Install a new fuel pump module O-ring to the fuel tank opening.
4. Pull the jet line quick-connectors up through the pump module opening, connecting the lines to the pump module as previously noted.
5. Install the pump module into the fuel tank, taking care not to damage the float arm.
6. Compress and align the fuel pump module, while installing the lock ring.
7. Using the J39765-A , fully lock the fuel pump module lock ring in place. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
8. Using a DMM, verify the full and empty readings resistance reading of the fuel pump module. Turn the fuel tank upside down to achieve the full tank reading. Resistance: Empty tank reading 247-253 ohms resistance Full tank reading 38.5-41.05 ohms resistance
9. Connect the jet line insert connector into the crossover tube to fuel tank opening.
10. If replacing the fuel pump module, install the FTP sensor (2). Refer to «Fuel Tank Pressure Sensor Replacement»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
11. Connect the FTP sensor harness connector (1).
12. Connect the fuel pump module harness connector (5).
13. Connect the EVAP purge line (4) from the fuel pump module.
14. Install the right fuel tank. Refer to «Fuel Tank Replacement - Right Side»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
15. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .

1. Remove the module from the fuel tank. Refer to «Fuel Tank Fuel Pump Module Replacement - Left Side (LS3, LS7)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) or «Fuel Tank Fuel Pump Module Replacement - Left Side (LS9)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
2. Press on the 3 connector position assurance (CPA) lock tabs (1) and slide downward.
3. Disconnect the electrical connector from the module.
4. Remove the sender wires from the connector.
5. Push in the lock tab (1) above the level sender body and slide the level sender out of the slot.
6. Remove the level sender from the module. Ensure wires are routed into the slot in the back of the level sender body.

1. Insert NEW level sender assembly into slot and slide down until lock tab (1) engages.
2. Route wires next to regulator ground wire and up to electrical connector.
3. Slide the level sender wires into the open slots in the electrical connector.
4. Connect the electrical connector into the flange.
5. Test the level sender resistance with an ohmmeter. Empty stop = 247-253 ohms. Full stop = 38.5-41.5 ohms. No open circuits along the full sweep.
6. Install module into tank. Refer to «Fuel Tank Fuel Pump Module Replacement - Left Side (LS3, LS7)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) or «Fuel Tank Fuel Pump Module Replacement - Left Side (LS9)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
7. Measure the resistance across the level sender with tank upright. Should read empty tank.
8. Roll tank over. Resistance should read full stop.
9. Return tank to upright position. Ensure proper empty stop resistance. This is done to ensure the level sender operates freely inside the tank and is not hung up on any of the internal lines.

1. Remove the module from the fuel tank. Refer to «Fuel Tank Fuel Pump Module Replacement - Right Side»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
2. Press on the connector position assurance (CPA) with thumb and slide toward downward.
3. Disconnect the electrical connector from the module.
4. Remove the sender wires from the electrical connector.
5. Push in the locktab above the level sender body and slide the level sender out of the slot.
6. Remove the level sender from the module. Ensure wires are routed into the slot in the back of the level sender body.

1. Insert NEW level sender assembly into slot and slide down until lock tab engages.
2. Route wires next to regulator ground wire and up to electrical connector.
3. Slide the level sender wires into the open slots in the electrical connector.
4. Connect the electrical connector into the flange.
5. Test the level sender resistance with an ohmmeter. Empty stop = 247-253 ohms Full stop = 38.5-41.5 ohms No open circuits along the full sweep
6. Install module into tank. Refer to «Fuel Tank Fuel Pump Module Replacement - Right Side»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
7. Measure the resistance across the level sender with tank upright. Should read empty tank.
8. Roll tank over. Resistance should read full stop.
9. Return tank to upright position. Ensure proper empty stop resistance. This is done to ensure the level sender operates freely inside the tank and is not hung up on any of the internal lines.

1. J 34730-1A Fuel Pressure Gage. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
2. J 37088-A Fuel Line Disconnect Tool Set

1. Remove the engine sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement (LS9)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) or «Upper Intake Manifold Sight Shield Replacement (w/o LS9)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) .
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
3. Remove the left fuel rail cover.
4. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief (Without CH 48027)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction__fuel-pressure-relief-without-ch-48027) or «Fuel Pressure Relief (With CH 48027)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
5. Disconnect the quick-connect fitting at the fuel rail (1). Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
6. Disconnect the quick-connect fitting at the chassis fuel pipe (3). Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
7. Remove the fuel feed hose (2).
8. Cap the chassis fuel pipe and the fuel rail pipe in order to prevent possible fuel system contamination.
9. Inspect the hose for bends, for kinks, for chafing, and for cracks. Replace the hose as required.

1. Remove the caps from the chassis fuel pipe and the fuel rail pipe.
2. Connect the fuel feed hose (2) to the chassis fuel pipe (3). Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
3. Connect the fuel feed hose (2) to the fuel rail (1). Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
4. Tighten the fuel filler cap.
5. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
6. Perform the following procedure in order to 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.
7. Install the engine sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement (LS9)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) or «Upper Intake Manifold Sight Shield Replacement (w/o LS9)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) .
8. Program the transmitters. Refer to «Transmitter Programming (N. America and Japan, except Canada)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-n-america-and-japan) or «Transmitter Programming (Canada and Europe)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-canada-and-europe) or «Transmitter Programming (New RCDLR ONLY)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-new-rcdlr-only) .

1. Remove the engine sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement (LS9)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) or «Upper Intake Manifold Sight Shield Replacement (w/o LS9)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) .
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
3. Remove the left fuel rail cover.
4. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief (Without CH 48027)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction__fuel-pressure-relief-without-ch-48027) or «Fuel Pressure Relief (With CH 48027)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
5. Disconnect the fuel feed hose (2) from the chassis fuel feed pipe (3). Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
6. Cap the engine compartment fuel feed pipe.
7. Disconnect the chassis fuel and evaporative emission (EVAP) pipe retainer (1) from the upper front of dash mounting stud (3).
8. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
9. Remove the exhaust intermediate pipe.
10. Remove the floor panel tunnel reinforcement. Refer to «Floor Panel Tunnel Panel Reinforcement Replacement»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
11. Disconnect the chassis fuel pipe (5) from the underbody retainers (6).
12. Remove the chassis fuel pipe.

Note. Follow the same routing as the original pipe. Secure the pipe in order to prevent chafing. Do not kink or bend the pipe.

1. Install the chassis fuel pipe (5) into the underbody retainers (6).
2. Install the floor panel tunnel reinforcement. Refer to «Floor Panel Tunnel Panel Reinforcement Replacement»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
3. Install the exhaust intermediate pipe.
4. Lower the vehicle.
5. Remove the cap from the engine compartment fuel feed pipe.
6. Connect the chassis fuel and EVAP pipe retainer (1) at the upper front of dash mounting stud (3). Tighten: Tighten the fuel and EVAP pipe retainer nut to 6 N.m (53 lb in).
7. Connect the fuel feed hose (2) to the chassis fuel feed pipe (3). Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
8. Tighten the fuel filler cap.
9. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
10. Perform the following procedure in order to 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.
11. Install the engine sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement (LS9)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) or «Upper Intake Manifold Sight Shield Replacement (w/o LS9)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) .
12. Program the transmitters. Refer to «Transmitter Programming (N. America and Japan, except Canada)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-n-america-and-japan) or «Transmitter Programming (Canada and Europe)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-canada-and-europe) or «Transmitter Programming (New RCDLR ONLY)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-new-rcdlr-only) .

1. J 34730-1A Fuel Pressure Gage. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
2. J 37088-A Fuel Line Disconnect Tool Set

Cleaning Procedure

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
2. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief (Without CH 48027)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction__fuel-pressure-relief-without-ch-48027) or «Fuel Pressure Relief (With CH 48027)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
3. Drain the fuel tanks. Refer to «Fuel Tank Draining»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
4. Remove the fuel tanks. For the left fuel tank, refer to «Fuel Tank Replacement - Left Side»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) . For the right fuel tank, refer to «Fuel Tank Replacement - Right Side»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
5. Remove the fuel sender assemblies.
6. Inspect the left fuel sender strainer. Replace a contaminated strainer for the left fuel sender only, and inspect the fuel pump.
7. Inspect the left fuel sender fuel pump inlet for debris. Replace the left fuel sender assembly if you find debris in the fuel pump inlet.
8. Inspect the right fuel sender strainers. Replace the right fuel sender assembly if you find a contaminated strainer. The right fuel sender strainers are not serviced separately.
9. Flush the fuel tanks with hot water.
10. Pour the water out of the fuel sender assembly openings. Rock the tanks to be sure that removal of the water from the tanks is complete.
11. Install the fuel sender assemblies.
12. Install the fuel tanks. For the left fuel tank, refer to «Fuel Tank Replacement - Left Side»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) . For the right fuel tank, refer to «Fuel Tank Replacement - Right Side»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
13. Refill the fuel system.
14. Install the fuel filler cap.
15. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
16. Perform the following procedure in order to 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.
17. Program the transmitters. Refer to «Transmitter Programming (N. America and Japan, except Canada)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-n-america-and-japan) or «Transmitter Programming (Canada and Europe)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-canada-and-europe) or «Transmitter Programming (New RCDLR ONLY)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-new-rcdlr-only) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
2. Remove the upper intake cover. Refer to «Upper Intake Manifold Sight Shield Replacement (LS9)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) or «Upper Intake Manifold Sight Shield Replacement (w/o LS9)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) .
3. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Without CH 48027)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction__fuel-pressure-relief-without-ch-48027) or «Fuel Pressure Relief (With CH 48027)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction)
4. Remove the front charge air cooler manifold. Refer to «Charge Air Cooler Replacement»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8)
5. Disconnect the fuel injection Harness connectors (1, 4).
6. Disconnect the MAP sensor harness connector (2).
7. Disconnect the supercharger air output sensor harness connector (3).
8. Disconnect the intake temperature sensor harness connector (5).
9. Disconnect and place aside the PCV tube (6).
10. Disconnect all 8 ignition coil harness connectors (1).
11. Remove the front fuel rail fastener (1).
12. Remove the fuel rail ball stud fasteners (2).
13. Carefully disengage the fuel injectors (3) from the supercharger.
14. Remove the fuel rail with the fuel injector harness (5) from the engine.
15. Remove the fuel injection wiring harness (2, 3) from the fuel rail (1) and fuel injectors.
16. If replacing the fuel rail of an injector. Refer to «Fuel Injector Replacement»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .

1. Install the fuel injectors. Refer to «Fuel Injector Replacement»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
2. Install the fuel injection wiring harness (2, 3) to the fuel rail (1) and fuel injectors.
3. Install the fuel rail with the fuel injector harness (5) to the engine.
4. Carefully locate the fuel injectors (3) into the supercharger. Install the left side first and then the right side.
5. Apply threadlock to the ball stud and fastener threads. Refer to «Adhesives, Fluids, Lubricants, and Sealers (6.2L LS3)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-1-of-8__adhesives-fluids-lubricants-and-sealers-62l) or «Adhesives, Fluids, Lubricants, and Sealers (6.2L LS9)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-1-of-8__adhesives-fluids-lubricants-and-sealers-62l) or «Adhesives, Fluids, Lubricants, and Sealers (7.0L)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-1-of-8__adhesives-fluids-lubricants-and-sealers-70l) .
6. Instal the ball studs (4) and the forward fastener (1) and tighten to 10 N.m (89 lb in).
7. Connect all 8 ignition coil harness connectors (1).
8. Connect the fuel injection Harness connectors (1, 4).
9. Connect the MAP sensor harness connector (2).
10. Connect the supercharger air output sensor harness connector (3).
11. Connect the intake temperature sensor harness connector (5).
12. Connect the PCV tube (6).
13. Install the front charge air cooler manifold. Refer to «Charge Air Cooler Replacement»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8)
14. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
15. Pressure the fuel system and check for fuel leaks.
16. Install the upper intake cover. Refer to «Upper Intake Manifold Sight Shield Replacement (LS9)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) or «Upper Intake Manifold Sight Shield Replacement (w/o LS9)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) .

Scheme 47

Scheme 48

1. J 37287 Fuel Line Shut-Off Adapters. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
2. J 35800-A Fuel Injector Cleaner
3. J 42873-1 3/8 Fuel Line Shut-Off Valve
4. J 42873-2 5/16 Return Pipe Shut-Off Valve
5. J 42964-1 3/8 Fuel Pipe Shut-Off Valve
6. J 42964-2 5/16 Fuel Pipe Shut-Off Valve

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

1. Obtain J 35800-A (2).
2. For 4, 5, and 6 cylinder engines, empty two of the 30 ml (1 oz.) reservoirs of the GM Upper Engine and Fuel Injector Cleaner twin reservoir container into the J 35800-A , injector cleaning tank, then add 420 ml (14 oz.) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz.) of GM Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz.) of regular unleaded gasoline.
3. For 8 cylinder engines, empty two of the 30 ml (1 oz.) reservoirs of the GM Upper Engine and Fuel Injector Cleaner twin reservoir container into the J 35800-A , injector cleaning tank, then add 420 ml (14 oz.) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz.) of GM Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz.) of regular unleaded gasoline. This procedure will need to be repeated for an 8 cylinder engine. The 8 cylinder engines receive 960 ml total fluidic ml (4 oz.) of GM Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz.) of gasoline.
4. Fill the injector cleaning tank with regular unleaded gasoline. Be sure to follow all additional instructions provided with the tool.
5. Electrically disable the vehicle fuel pump by removing the fuel pump relay and disconnecting the oil pressure switch connector, if equipped.
6. Disconnect the fuel feed and return line, if equipped, at the fuel rail. Plug the fuel feed and return line, if equipped, coming off the fuel rail with J 37287 , or J 42964-1 , and J 42964-2 or J 42873-1 , and J 42873-2 as appropriate for the fuel system.
7. Connect the J 35800-A to the vehicle fuel rail.
8. Pressurize the J 35800-A to 510 kPa (75 psi).
9. Start and idle the engine until it stalls due to lack of fuel. This should take approximately 15-20 minutes.
10. Turn the ignition to the OFF position.
11. Injectors should be flow-tested at this point. If further cleaning is needed, a repeat of the above procedure should be done. When the injector restriction returns to zero, proceed to step 12.
12. Disconnect the J 35800-A from the fuel rail.
13. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped.
14. Remove the J 37287 , or J 42964-1 and J 42964-2 , or J 42873-1 and J 42873-2 and reconnect the vehicle fuel feed and return lines.
15. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines.
16. Pour the entire contents of GM Fuel System Treatment Plus, GM P/N 88861011 (Canadian P/N 88861012) into a nearly empty tank and advise the customer to refuel with up to 76 L (20 gal) of fuel.
17. Advise the customer to use only a Top Tier Detergent gasoline and to add a bottle of GM Fuel System Treatment Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should keep the customer from having to repeat the injector cleaning procedure.
18. Road test the vehicle to verify that the customer concern has been corrected.

Scheme 49

Scheme 50

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
2. Disconnect the evaporative emission (EVAP) canister valve harness connector.
3. Disconnect the vent hose (2) from the EVAP canister vent valve (1).
4. Remove the EVAP canister vent valve (2) from the vent bracket (1).

1. Install the EVAP canister vent valve (2) to the vent bracket (1).
2. Connect the vent hose (2) to the EVAP canister vent valve (1).
3. Connect the EVAP vent valve electrical connector.
4. Lower the vehicle.

Scheme 51

1. Remove the engine sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement (LS9)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) or «Upper Intake Manifold Sight Shield Replacement (w/o LS9)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) .
2. Disconnect the quick-connect fittings at the evaporative emission (EVAP) canister purge valve (7). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
3. Remove the EVAP pipe (2).

1. Install the EVAP pipe (2) to the EVAP canister purge valve (7).
2. Connect the EVAP pipe (2) to the connection for the canister at the left rear of the engine.
3. Install the engine sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement (LS9)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) or «Upper Intake Manifold Sight Shield Replacement (w/o LS9)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) .

1. Disconnect the engine purge pipe (1) from the chassis purge pipe (2).
2. Cap the engine purge pipe in order to prevent possible contamination.
3. Disconnect the chassis fuel and evaporative emission (EVAP) pipe retainer (1) from the upper front of dash mounting stud (3).
4. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
5. Remove the exhaust intermediate pipe. Refer to «Intermediate Pipe Replacement»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) .
6. Remove the floor panel tunnel reinforcement. Refer to «Floor Panel Tunnel Panel Reinforcement Replacement»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
7. Remove the EVAP canister vent valve (2) from the bracket (1).
8. Disconnect the rear purge pipe (1) at the chassis purge pipe (3).
9. Cap the rear purge pipe.
10. Remove the chassis purge pipe (4) rear underbody retainer nuts (3).
11. Remove the chassis purge pipe (4) from the rear underbody retainers (2).
12. Disconnect the chassis purge pipe (4) from the side underbody retainers (6).
13. Remove the chassis purge pipe.

1. Install the chassis purge pipe (4) into the side underbody retainers (6).
2. Install the chassis purge pipe (4) into the rear underbody retainers (2).
3. Install the underbody retainers (2) on the mounting studs (1).
4. Install the chassis purge pipe (4) underbody retainer nuts (3). Tighten: Tighten the EVAP pipe retainer bracket nuts to 6 N.m (53 lb in).
5. Uncap the rear EVAP pipe.
6. Connect the rear EVAP pipe (1) to the chassis purge pipe (3).
7. Install the EVAP canister vent valve (2) to the bracket (1).
8. Install the floor panel tunnel reinforcement. Refer to «Floor Panel Tunnel Panel Reinforcement Replacement»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
9. Install the exhaust intermediate pipe.
10. Lower the vehicle.
11. Uncap the engine purge pipe.
12. Connect the chassis fuel and EVAP pipe retainer (1) at the upper front of dash mounting stud (3). Tighten: Tighten the fuel and EVAP pipe bracket retainer nut to 6 N.m (53 lb in).
13. Connect the engine purge pipe (1) to the chassis purge pipe (2).

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
2. For vehicles equipped with an automatic transmission, remove the right muffler. Refer to «Exhaust Muffler Replacement - Right Side»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) .
3. Remove the evaporative emission (EVAP) vent valve (2) from the bracket (1).
4. Disconnect the rear EVAP purge pipe (1) at the chassis EVAP purge pipe (3).
5. Cap the chassis EVAP purge pipe.
6. Remove the right rear wheelhouse panel. Refer to «Rear Wheelhouse Panel Liner Replacement»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
7. Remove the EVAP canister access cover.
8. Disconnect the EVAP purge pipe at the canister.
9. Remove the rear EVAP purge pipe.

1. Route the EVAP purge pipe through the right tunnel brace opening.
2. Connect the EVAP purge pipe to the canister.
3. Remove the cap from the chassis EVAP purge pipe.
4. Connect the rear EVAP purge pipe (1) to the chassis EVAP purge pipe (3).
5. Install the EVAP vent valve (2) to the bracket (1).
6. For vehicles equipped with automatic transmission, install the right muffler. Refer to «Exhaust Muffler Replacement - Right Side»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) .
7. Install the EVAP canister access cover.
8. Install the right rear wheelhouse panel. Refer to «Rear Wheelhouse Panel Liner Replacement»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
9. Lower the vehicle.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
2. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief (Without CH 48027)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction__fuel-pressure-relief-without-ch-48027) or «Fuel Pressure Relief (With CH 48027)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
3. Drain the fuel tanks below the level of the fuel tank crossover hose. Refer to «Fuel Tank Draining»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
4. For vehicles equipped with automatic transmission, remove the left and right muffler. Refer to «Exhaust Muffler Replacement - Right Side»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) , and to «Exhaust Muffler Replacement - Left Side»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) .
5. Disconnect the tank crossover hose (5) at the right fuel tank and the left fuel tank.
6. Disconnect the evaporative emission (EVAP) pipe (2) at the right tank EVAP pipe (3) and the left tank EVAP pipe (1).
7. Remove the rear EVAP pipe (2).
8. Cap the open pipes in order to prevent possible contamination.

1. Remove the caps from the pipes.
2. Connect the EVAP pipe (2) at the right tank EVAP pipe (3) and the left tank EVAP pipe (1).
3. Connect the tank crossover hose (5) at the right fuel tank and the left fuel tank.
4. Push the clamp (4) outboard against the fuel tank, keeping the clamp parallel with the white stripe on the tank crossover hose. Tighten: Tighten the tank crossover hose clamps to 4 N.m (35 lb in).
5. Install the right and left muffler. Refer to «Exhaust Muffler Replacement - Right Side»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) and to «Exhaust Muffler Replacement - Left Side»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) .
6. Refill the fuel system.
7. Tighten the fuel filler cap.
8. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
9. Use the following procedure in order to inspect for leaks: Turn the ignition switch ON, with the engine OFF for 2 seconds. Turn the ignition switch OFF, for 10 seconds. Turn the ignition switch ON, with the engine OFF. Inspect for fuel leaks.
10. Program the transmitters. Refer to «Transmitter Programming (N. America and Japan, except Canada)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-n-america-and-japan) or «Transmitter Programming (Canada and Europe)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-canada-and-europe) or «Transmitter Programming (New RCDLR ONLY)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-new-rcdlr-only) .

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
2. For vehicles equipped with automatic transmission, remove the right muffler. Refer to «Exhaust Muffler Replacement - Right Side»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) .
3. Disconnect the vent hose (2) from the evaporative emission (EVAP) vent valve (1).
4. Remove the clamp from the vent hose.
5. Remove the right rear wheelhouse panel. Refer to «Rear Wheelhouse Panel Liner Replacement»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
6. Remove the EVAP canister access cover.
7. Disconnect the vent hose from the EVAP canister.
8. Remove the vent hose.
9. Cap the EVAP vent valve and the EVAP canister in order to prevent possible EVAP system contamination.

1. Remove the caps from the EVAP vent valve and the EVAP canister.
2. Route the vent hose over the floor panel tunnel panel rear brace.
3. Install the clamps on the vent hose.
4. Connect the vent hose to the EVAP canister.
5. Connect the vent hose (2) to the EVAP vent valve.
6. For vehicles equipped with automatic transmission, install the right muffler. Refer to «Exhaust Muffler Replacement - Right Side»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) .
7. Install the EVAP canister access cover.
8. Install the right rear wheelhouse panel. Refer to «Rear Wheelhouse Panel Liner Replacement»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
9. Lower the vehicle.

1. Remove the right fuel tank.
2. Disconnect the vent hose from the evaporative emission (EVAP) canister.
3. Disconnect the purge pipe at the EVAP canister.
4. Remove the EVAP canister bracket bolt (3).
5. Remove the EVAP canister (1) from the EVAP canister bracket (2).

1. Install the new EVAP canister (1) to the EVAP canister bracket (2).
2. Install the EVAP canister bracket bolt (3). Tighten: Tighten the EVAP canister bracket bolt to 7 N.m (62 lb in).
3. Connect the purge pipe at the EVAP canister.
4. Connect the vent hose to the EVAP canister.
5. Install the right fuel tank.

Scheme 52

Spark Plug Wire Inspection

Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions

1. Correct routing of the spark plug wires. Incorrect routing may cause cross-firing.
2. Any signs of cracks or splits in the wires.
3. 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 on a terminal, replace the wire and the component connected to the wire.

1. Disconnect the spark plug wires at each spark plug: Twist each spark plug boot 1/2 turn. Pull only on the boot in order to remove the wire from each spark plug.
2. Disconnect the spark plug wires from the ignition coil: Twist each spark plug boot 1/2 turn. Pull only on the boot in order to remove the wires from the ignition coil.

1. Install the spark plug wires at the ignition coil.
2. Install the spark plug wire to each spark plug.
3. Inspect the wires for proper installation: Push sideways on each boot in order to inspect the seating. Reinstall any loose boot.

Spark Plug Usage

1. Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to «Ignition System Specifications»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction__ignition-system-specifications) for the correct spark plug.
2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling - colder plug Pre-ignition causing spark plug and/or engine damage - hotter plug

Spark Plug Inspection

1. 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.
2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground.
3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4).
4. Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to «Ignition System Specifications»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-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/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-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 reduce or eliminates the gap. Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. Inspect for excessive fouling.
5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation.

Spark Plug Visual Inspection

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

1. Remove the fuel rail covers.
2. Remove the spark plug wires. Refer to «Spark Plug Wire Replacement»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
3. Loosen each spark plug 1 or 2 turns.
4. Brush or use compressed air to remove any dirt around the spark plugs.
5. Remove the spark plugs one at a time and place each plug in a tray marked with the corresponding cylinder numbers.

1. Inspect each spark plug gap. Adjust each plug as needed. Specification: Spark plug gap: 1.016 mm (0.040 in)
2. Hand start the spark plugs in the corresponding cylinders.
3. Tighten the spark plugs. Tighten: For cylinder head-new: Tighten the spark plugs to 20 N.m (15 lb ft). For cylinder head-all subsequent installations: Tighten the spark plugs to 15 N.m (11 lb ft).
4. Install the spark plug wires. Refer to «Spark Plug Wire Replacement»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
5. Install the fuel rail covers.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
3. Remove the starter. Refer to «Starter Replacement»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
4. Disconnect the crankshaft position (CKP) sensor electrical connector.
5. Remove the CKP sensor retaining bolt.
6. Remove the CKP sensor.

1. Install the CKP sensor.
2. Install the CKP sensor retaining bolt. Tighten: Tighten the CKP sensor to 25 N.m (18 lb ft).
3. Connect the CKP sensor electrical connector.
4. Install the starter. Refer to «Starter Replacement»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
5. Lower the vehicle.
6. Connect the negative battery cable.
7. Program the transmitters. Refer to «Transmitter Programming (N. America and Japan, except Canada)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-n-america-and-japan) or «Transmitter Programming (Canada and Europe)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-canada-and-europe) or «Transmitter Programming (New RCDLR ONLY)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-new-rcdlr-only) .
8. Perform the CKP System Variation Learn Procedure. Refer to «Crankshaft Position System Variation Learn»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction__crankshaft-position-system-variation-learn) .

1. Remove the generator bracket assembly. Refer to «Generator Bracket Replacement»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
2. Remove the camshaft position sensor mounting bolts (1).
3. Remove the camshaft position sensor assembly (4, 5, 6) from the front cover (7).
4. Disconnect the camshaft position sensor jumper harness (2) and the engine harness (3) electrical connectors.
5. Remove the camshaft sensor assembly (4, 5, 6).
6. Disconnect camshaft position sensor (5) from the jumper harness (4).

1. Reconnect the camshaft sensor (5) and the jumper harness (4).
2. Install the O-ring (6) on the camshaft sensor assembly (4 and 5).
3. Reconnect the camshaft position sensor assembly (4, 5 and 6) and the engine harness connector (3).
4. Install the camshaft position sensor assembly (4, 5 and 6) in the front cover (7).
5. Install the camshaft position sensor mounting bolts. Tighten: Tighten the camshaft position mounting bolts 25 N.m (18 lb ft).
6. Install the generator assembly. Refer to «Generator Bracket Replacement»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .

1. Remove the right exhaust manifold. Refer to «Exhaust Manifold Replacement - Right Side (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Right Side (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) .
2. Remove the right catalytic convertor. Refer to «Catalytic Converter Replacement - Right Side (7.0L)»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) .
3. Remove the starter assembly (4), ONLY IF NEEDED. Refer to «Starter Replacement»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
4. Remove the knock sensor mounting (1).
5. Remove the knock sensor (2) from the engine block (5).
6. Disconnect the engine electrical connector (3) from the knock sensor (2).
7. Remove the knock sensor (2).

1. Reconnect electrical connector (3) for the engine harness to the knock sensor (2).
2. Position the knock sensor (2) on the engine block (5).
3. Install the mounting bolt (1) for the knock sensor (2).
4. Tighten the knock sensor mounting bolt (1). Tighten: Tighten the knock sensor mounting bolt 1 to 20 N.m (15 lb ft).
5. Install the starter assembly (4), ONLY IF REMOVED. Refer to «Starter Replacement»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
6. Install the right catalytic convertor. Refer to «Catalytic Converter Replacement - Right Side (7.0L)»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) .
7. Install the right exhaust manifold. Refer to «Exhaust Manifold Replacement - Right Side (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Right Side (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) .
8. Program the transmitters. Refer to «Transmitter Programming (N. America and Japan, except Canada)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-n-america-and-japan) or «Transmitter Programming (Canada and Europe)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-canada-and-europe) or «Transmitter Programming (New RCDLR ONLY)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-new-rcdlr-only) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
2. Remove the left catalytic convertor. Refer to «Catalytic Converter Replacement - Left Side (7.0L)»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) .
3. Remove the left exhaust manifold. Refer to «Exhaust Manifold Replacement - Left Side (With LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Left Side (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) .
4. Remove the mounting bolt for the knock sensor 1.
5. Disconnect the electrical connector of the knock sensor from the engine harness (3).
6. Remove the knock sensor (2) from the engine block (4).

1. Reconnect the engine harness (3) and the knock sensor (2) electrical connectors.
2. Position the knock sensor 2 on the engine block (4).
3. Install the mounting bolt (1) for the knock sensor 2.
4. Tighten the knock sensor mounting bolt (1). Tighten: Tighten the knock sensor mounting bolt to 20 N.m (15 lb ft).
5. Install the left exhaust manifold. Refer to «Exhaust Manifold Replacement - Left Side (With LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Left Side (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) .
6. Install the left catalytic convertor. Refer to «Catalytic Converter Replacement - Left Side (7.0L)»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) .
7. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
8. Program the transmitters. Refer to «Transmitter Programming (N. America and Japan, except Canada)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-n-america-and-japan) or «Transmitter Programming (Canada and Europe)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-canada-and-europe) or «Transmitter Programming (New RCDLR ONLY)»(/chevrolet/corvette/c6-2004-2014/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__transmitter-programming-new-rcdlr-only) .

Scheme 53

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement (6.2L)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) or «Air Cleaner Assembly Replacement (7.0L)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) or «Air Cleaner Assembly Replacement (LS9)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .
2. Remove the bolts holding the air filter retainer to the air cleaner assembly.
3. Remove the air filter.

1. Install the air filter.
2. Install the air filter retainer to the air cleaner assembly.
3. Tighten the bolts.
4. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement (6.2L)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) or «Air Cleaner Assembly Replacement (7.0L)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) or «Air Cleaner Assembly Replacement (LS9)»(/chevrolet/corvette/c6-2004-2014/remont/testing-diagnostics/#engine-controls-and-fuel-62l-or-70l-introduction) .

Scheme 54

1. Disconnect the electrical connector for the mass air flow (MAF)/intake air temperature (IAT) sensor.
2. Loosen the clamp.
3. Remove the bolts holding the air cleaner assembly to the radiator core support.
4. Remove the air cleaner assembly.

1. Install the air cleaner assembly.
2. Tighten the hose clamp.
3. Install the bolts holding the air cleaner assembly to the radiator core support.
4. Connect the electrical connector for the MAF/IAT sensor.

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Engine Control Module Description

The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs the diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM 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 ECM.

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 61

Scheme 62

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

1. 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.
2. The MIL turns OFF after the engine is started if a diagnostic fault is not present.
3. 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.
4. The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter.
5. When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON.
6. When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON.

Scheme 63

The engine control module (ECM) is the control center for the throttle actuator control (TAC) system. The ECM determines the driver's intent based on input form the accelerator pedal position sensors, then calculates the appropriate throttle response based on the throttle position sensors. The ECM achieves throttle positioning by providing a pulse width modulated voltage to the throttle actuator motor. The throttle blade is spring loaded in both directions, and the default position is slightly open.

Normal Mode

During the operation of the TAC system, several modes, or functions, are considered normal. The following modes may be entered during normal operations

1. Minimum pedal value-At key-up, the ECM updates the learned minimum pedal value.
2. Minimum throttle position values-At key-up, the ECM updates the learned minimum throttle position value. In order to learn the minimum throttle position value, the throttle blade is moved to the Closed position.
3. Ice break mode-If the throttle blade is not able to reach a predetermined minimum throttle position, the ice break mode is entered. During the ice break mode, the ECM commands the maximum pulse width several times to the throttle actuator motor in the closing direction.
4. Minimum pedal value-At key-up, the ECM updates the learned minimum pedal value.
5. Battery saver mode-After a predetermined time without engine RPM, the ECM 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 ECM detects a condition with the TAC system, the ECM may enter a reduced engine power mode. Reduced engine power may cause one or more of the following conditions

1. Acceleration limiting-The ECM will continue to use the accelerator pedal for throttle control, however, the vehicle acceleration is limited.
2. Limited throttle mode-The ECM will continue to use the accelerator pedal for throttle control, however, the maximum throttle opening is limited.
3. Throttle default mode-The ECM will turn OFF the throttle actuator motor, and the throttle will return to the spring loaded default position.
4. Forced idle mode-The ECM will perform the following actions: Limit engine speed to idle positioning the throttle position, or by controlling the fuel and spark if the throttle is turned OFF. Ignore the accelerator pedal input.
5. Engine shutdown mode-The ECM will disable fuel and de-energize the throttle actuator.

Fuel Tank

The fuel storage tank is made of high density polyethylene. The fuel storage tank is held in place by 2 metal straps that are attached to the under body of the vehicle. The tank shape includes a sump in order to maintain a constant supply of fuel around the fuel pump strainer during low fuel conditions or during aggressive maneuvers.

The fuel tank also contains a fuel vapor vent valve with a roll-over protection. The vent valve also features a 2-phase vent calibration which increases the fuel vapor flow to the canister when the operating temperatures increase the tank pressure beyond an established threshold.

On-Board Refueling Vapor Recovery (ORVR) System

The on-board refueling vapor recovery (ORVR) system is an on-board vehicle system to recover fuel vapors during the vehicle refueling operation. The flow of liquid fuel down to the fuel tank filler neck provides a liquid seal. The purpose of ORVR is to prevent refueling vapor from exiting the fuel tank filler neck. The ORVR components are listed below, with a brief description of their operation

1. The fuel tank-The fuel tank contains the modular fuel sender, the fuel limiter vent valve (FLVV), and 1 rollover valve.
2. The fuel filler pipe-The fuel filler pipe carries fuel from the fuel nozzle to the fuel tank.
3. The evaporative emission (EVAP) canister-The EVAP canister receives refueling vapor from the fuel system, stores the vapor, and releases the vapor to the engine upon demand.
4. The vapor lines-The vapor lines transport fuel vapor from the tank assembly to the EVAP canister and engine.
5. The check valve-The check valve limits fuel spit-back from the fuel tank during the refueling operation by allowing fuel flow only into the fuel tank. The check valve is located at the bottom of the fuel filler pipe.
6. The modular fuel sender assembly-The modular fuel sender assembly pumps fuel to the engine from the fuel tank.
7. The fuel tank pressure (FTP) sensor is located on top of the fuel tank vapor dome.
8. The FLVV-The FLVV acts as a shut-off valve. The FLVV is located in the fuel tank. This valve has the following functions: Controlling the fuel tank fill level by closing the primary vent from the fuel tank Preventing fuel from exiting the fuel tank via the vapor line to the canister Providing fuel spillage protection in the event of a vehicle rollover by closing the vapor path from the tank to the engine
9. The pressure vacuum relief valve-The pressure vacuum relief valve provides venting of excessive fuel tank pressure and vacuum. The valve is located in the fuel fill cap.
10. The vapor recirculation line-The vapor recirculation line is used to transport vapor from the fuel tank to the top of the fill pipe during refueling to reduce vapor loading to the enhanced EVAP canister.

Fuel Tank Filler Pipe

In order to prevent refueling with leaded fuel, the fuel filler pipe has a built-in restrictor and a deflector. The opening in the restrictor will accept only the smaller unleaded gasoline fuel nozzle which must be fully inserted in order to bypass the deflector. The tank is vented during filling by an internal vent tube inside of the filler pipe.

Scheme 64

The fuel tank filler pipe is equipped with a turn to vent screw on the type cap which incorporates a ratchet action in order to prevent over-tightening.

The turn to vent feature allows the fuel tank pressure relief prior to removal. Instructions for proper use are imprinted on the cap cover. A vacuum safety relief valve is incorporated into this cap.

Modular Fuel Sender

The modular fuel sender assembly mounts to the threaded opening of the plastic fuel tank with a seal and a retainer ring. The reservoir, containing the exterior inlet strainer, the electric fuel pump and the pump strainer, maintains contact with the tank bottom. This design provides

1. Optimum fuel level in the integral fuel reservoir during all fuel tank levels and during driving conditions
2. An improved tank fuel level measuring accuracy
3. An improved coarse straining and added pump inlet filtering
4. More extensive internal fuel pump isolation for noiseless operation

The modular fuel sender assembly maintains an optimum fuel level in the reservoir (bucket). The fuel entering the reservoir is drawn in by the following components

1. The first stage of the fuel pump through the external strainer and/or
2. The secondary umbrella valve or
3. The return fuel line, whenever the level of fuel is below the top of the reservoir

Fuel Pump

The electric fuel pump is a screw type pump which is located inside of the modular fuel sender. The electric fuel pump operation is controlled by the FSCM and 3 phase control module.

Electronic Returnless Fuel System (ERFS)

The electronic returnless fuel system is a microprocessor controlled fuel delivery system which transports fuel from the tank to the fuel rails. It functions as an electronic replacement for a traditional, mechanical fuel pressure regulator. A pressure vent valve within the fuel tank provides an added measure of over-pressure protection.

The electronic returnless fuel system (ERFS) is a demand based system which uses a fuel pump driven by a dedicated controller, the fuel pump control module (FPCM). Desired fuel pressure is commanded by the ECM and transmitted to the FPCM via a GMLAN message. A liquid fuel pressure sensor provides the feedback the FPCM requires for Closed Loop fuel pressure control. For the GMX 245 SS application, the FPCM drives the fuel pump control module relay, also referred to as the fuel pump delivery control module, to control the brushless, 3-phase fuel pump.

Fuel Pump Control Module (FPCM)

The fuel pump flow control module (FPCM) is a serviceable GMLAN device mounted on the left, rear corner under the rear compartment floor panel carpet of the vehicle. The FPCM receives the desired fuel pressure message from the engine control module (ECM) and drives the FPCM relay to control the 3-phase fuel pump, located within the fuel tank, to achieve the desired fuel pressure. A liquid pressure sensor provides fuel pressure feedback to the FPCM.

The FPCM provides a control enable input to the FPCM relay to turn the 3-phase fuel pump ON and OFF. The control enable input is switched to ground to turn ON the pump. The FPCM also sends a 400 HZ pulse width module (PWM) signal to the FPCM relay to control the fuel pump speed by varying the duty cycle of this signal.

Fuel Pump Control Module Relay

The fuel pump control module (FPCM) relay is a serviceable device mounted on the left, rear corner under the rear compartment floor panel carpet of the vehicle. The FPCM relay communicates with the FPCM via CAN serial data. The FPCM relay diagnostics are reported out via the FPCM. The FPCM relay controls the brushless, 3-phase fuel pump by providing variable, continuous PWM speed control. The nominal current supplied to the fuel pump is 15 amps, with a maximum limit of 25 amps.

Fuel Pressure Sensor

The fuel pressure sensor is a serviceable 5-volt, 3-pin device. It is located on the fuel feed line forward of the fuel tank, and receives power and ground from the fuel pump control module (FPCM) through a vehicle wiring harness. The sensor provides a fuel pressure signal to the FPCM, which is used to provide Closed Loop fuel pressure control.

Fuel Sender Strainers

The strainers act as a coarse filter to perform the following functions

1. Filter contaminants
2. Separate water from fuel
3. Provide a wicking action that helps draw fuel into the fuel pump

Fuel stoppage at the strainer indicates that the fuel tank contains an abnormal amount of sediment or water. Therefore, the fuel tank will need to be removed and cleaned, and the filter strainer should be replaced.

In-Line Fuel Filter

The fuel filter is located on the fuel feed pipe, between the fuel pump and the fuel rail. The electric fuel pump supplies fuel through the in-line fuel filter to the fuel injection system. The fuel pressure regulator keeps the fuel available to the fuel injectors at a regulated pressure. Unused fuel is returned from the fuel filter to the fuel tank by a separate fuel return pipe. 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.

EVAP Lines and Hoses

The EVAP line extends from the fuel tank vent valve to the EVAP canister and into the engine compartment. The EVAP line is made of nylon and connects to the EVAP canister with a quick connect fitting.

Fuel Pressure Regulator

The fuel pressure regulator attaches to the fuel return pipe on the fuel sender assembly. The fuel pressure regulator is a diaphragm-operated relief valve. A software bias compensates the injector on-time because the fuel pressure regulator is not referenced to manifold vacuum. The injector pulse width varies with the signal from the mass air flow (MAF)/intake air temperature (IAT) sensor.

With the engine running at idle, the system fuel pressure at the pressure test connection should be between 240-265 kPa (35-39 psi). With the system pressurized and the pump OFF the pressure should stabilize and hold. If the pressure regulator supplies a fuel pressure which is too low or too high, a driveability condition will result.

Fuel Rail

The fuel rail consists of 3 parts

1. The pipe that carries fuel to each injector
2. The fuel pressure test port
3. Eight individual fuel injectors

The fuel rail is mounted on the intake manifold and distributes the fuel to each cylinder through the individual injectors.

Fuel Injectors

The fuel injector is a solenoid device that is controlled by the ECM. When the ECM energizes the injector coil, a normally closed ball valve opens, allowing the fuel to flow past a director plate to the injector outlet. The director plate has holes that control the fuel flow, generating a dual conical spray pattern of finely atomized fuel at the injector outlet. The fuel from the outlet is directed at both of the intake valves, causing the fuel to become further vaporized before entering the combustion chamber.

The fuel injectors will cause various driveability conditions if the following conditions occur

1. If the injectors will not open
2. If the injectors are stuck open
3. If the injectors are leaking
4. If the injectors have a low coil resistance

Engine Fueling

The engine is fueled by individual injectors, one for each cylinder, that are controlled by the ECM. The ECM controls each injector by energizing the injector coil for a brief period once every other engine revolution. The length of this brief period, or pulse, is carefully calculated by the ECM to deliver the correct amount of fuel for proper driveability and emissions control. The period of time when the injector is energized is called the pulse width and is measured in milliseconds, thousandths of a second.

While the engine is running, the ECM is constantly monitoring the inputs and recalculating the appropriate pulse width for each injector. The pulse width calculation is based on the injector flow rate, mass of fuel the energized injector will pass per unit of time, the desired air/fuel ratio, and actual air mass in each cylinder and is adjusted for battery voltage, short term, and long term fuel trim. The calculated pulse is timed to occur as each cylinders intake valves are closing to attain largest duration and most vaporization.

Fueling during a crank is slightly different than fueling during an engine run. As the engine begins to turn, a prime pulse may be injected to speed starting. As soon as the ECM can determine where in the firing order the engine is, the ECM begins pulsing the injectors. The pulse width during the crank is based on the coolant temperature and the engine load.

The fueling system has several automatic adjustments in order to compensate for the differences in the fuel system hardware, the driving conditions, the fuel used, and the vehicle aging. The basis for the fuel control is the pulse width calculation that is described above. Included in this calculation are an adjustment for the battery voltage, the short term fuel trim, and the long term fuel trim. The battery voltage adjustment is necessary since the changes in the voltage across the injector affect the injector flow rate. The short term and the long term fuel trims are fine and gross adjustments to the pulse width that are designed in order to maximize the driveability and emissions control. These fuel trims are based on the feedback from the oxygen sensors in the exhaust stream and are only used when the fuel control system is in a Closed Loop operation.

Under certain conditions, the fueling system will turn OFF the injectors for a period of time. This is referred to as fuel shut-off. Fuel shut-off is used in order to improve traction, save fuel, improve emissions, and protect the vehicle under certain extreme or abusive conditions.

In case of a major internal problem, the ECM may be able to use a back-up fuel strategy for limp in mode that will run the engine until service can be performed.

Sequential Fuel Injection (SFI)

The ECM controls the fuel injectors based on information that the ECM receives from several information sensors. Each injector is fired individually in the engine firing order, which is called sequential fuel injection. This allows precise fuel metering to each cylinder and improves the driveability under all of the driving conditions.

The ECM has several operating modes for fuel control, depending on the information that has been received from the sensors.

Starting Mode

When the ECM detects reference pulses from the CKP sensor, the ECM will enable the fuel pump. The fuel pump runs and builds up pressure in the fuel system. The ECM then monitors the MAF, IAT, engine coolant temperature (ECT), and the throttle position (TP) sensor signal in order to determine the required injector pulse width for starting.

Clear Flood Mode

If the engine is flooded with fuel during starting and will not start, the Clear Flood Mode can be manually selected. To select Clear Flood Mode, push the accelerator to wide open throttle (WOT). With this signal, the ECM will completely turn OFF the injectors and will maintain this stage as long as the ECM indicates a WOT condition with engine speed below 1,000 RPM.

Run Mode

The Run Mode has 2 conditions: Open Loop operation and Closed Loop operation. When the engine is first started and the engine speed is above 480 RPM, the system goes into Open Loop operation. In Open Loop operation, the ECM ignores the signals from the oxygen sensors and calculates the required injector pulse width based primarily on inputs from the MAF, IAT and ECT sensors.

In Closed Loop, the ECM adjusts the calculated injector pulse width for each bank of injectors based on the signals from each oxygen sensor.

Acceleration Mode

The ECM monitors the changes in the TP and the MAF sensor signals in order to determine when the vehicle is being accelerated. The ECM will then increase the injector pulse width in order to provide more fuel for improved performance.

Deceleration Mode

The ECM monitors changes in TP and MAF sensor signals to determine when the vehicle is being decelerated. The ECM will then decrease injector pulse width or even shut OFF injectors for short periods to reduce exhaust emissions, and for better (engine braking) deceleration.

Battery Voltage Correction Mode

The ECM can compensate in order to maintain acceptable vehicle driveability when the ECM sees a low battery voltage condition. The ECM compensates by performing the following functions

1. Increasing the injector pulse width in order to maintain the proper amount of fuel being delivered
2. Increasing the idle speed to increase the generator output

Fuel Shut-Off Mode

The ECM has the ability to completely turn OFF all of the injectors or selectively turn OFF some of the injectors when certain conditions are met. These fuel shut-off modes allow the ECM to protect the engine from damage and also to improve the vehicles driveability.

The ECM will disable all of the eight injectors under the following conditions

1. Ignition OFF-Prevents engine run-on
2. Ignition ON but no CKP signal-Prevents flooding or backfiring
3. A high engine speed-Above the red line
4. A high vehicle speed-Above the rated tire speed
5. Closed throttle cast down-Reduces the emissions and increases engine braking.

The ECM will selectively disable the injectors under the following conditions

1. The torque management enabled-Transmission shifts or abusive maneuvers.
2. The traction control enabled-In conjunction with the front brakes applying

The fuel storage tank is made of high density polyethylene. The fuel storage tank is held in place by 2 metal straps that are attached to the under body of the vehicle. The tank shape includes a sump in order to maintain a constant supply of fuel around the fuel pump strainer during low fuel conditions or during aggressive maneuvers.

The fuel tank also contains a fuel vapor vent valve with a roll-over protection. The vent valve also features a 2-phase vent calibration which increases the fuel vapor flow to the canister when the operating temperatures increase the tank pressure beyond an established threshold.

The on-board refueling vapor recovery (ORVR) system is an on-board vehicle system to recover fuel vapors during the vehicle refueling operation. The flow of liquid fuel down to the fuel tank filler neck provides a liquid seal. The purpose of ORVR is to prevent refueling vapor from exiting the fuel tank filler neck. The ORVR components are listed below, with a brief description of their operation

1. The fuel tank-The fuel tank contains the modular fuel sender, the fuel limiter vent valve (FLVV), and 1 rollover valve.
2. The fuel filler pipe-The fuel filler pipe carries fuel from the fuel nozzle to the fuel tank.
3. The evaporative emission (EVAP) canister-The EVAP canister receives refueling vapor from the fuel system, stores the vapor, and releases the vapor to the engine upon demand.
4. The vapor lines-The vapor lines transport fuel vapor from the tank assembly to the EVAP canister and engine.
5. The check valve-The check valve limits fuel spit-back from the fuel tank during the refueling operation by allowing fuel flow only into the fuel tank. The check valve is located at the bottom of the fuel filler pipe.
6. The modular fuel sender assembly-The modular fuel sender assembly pumps fuel to the engine from the fuel tank.
7. The fuel tank pressure (FTP) sensor is located on top of the fuel tank vapor dome.
8. The FLVV-The FLVV acts as a shut-off valve. The FLVV is located in the fuel tank. This valve has the following functions: Controlling the fuel tank fill level by closing the primary vent from the fuel tank Preventing fuel from exiting the fuel tank via the vapor line to the canister Providing fuel spillage protection in the event of a vehicle rollover by closing the vapor path from the tank to the engine
9. The pressure vacuum relief valve-The pressure vacuum relief valve provides venting of excessive fuel tank pressure and vacuum. The valve is located in the fuel fill cap.
10. The vapor recirculation line-The vapor recirculation line is used to transport vapor from the fuel tank to the top of the fill pipe during refueling to reduce vapor loading to the enhanced EVAP canister.

In order to prevent refueling with leaded fuel, the fuel filler pipe has a built-in restrictor and a deflector. The opening in the restrictor will accept only the smaller unleaded gasoline fuel nozzle which must be fully inserted in order to bypass the deflector. The tank is vented during filling by an internal vent tube inside of the filler pipe.

Fuel Filler Cap

The fuel tank filler pipe is equipped with a turn to vent screw on the type cap which incorporates a ratchet action in order to prevent over-tightening.

The turn to vent feature allows the fuel tank pressure relief prior to removal. Instructions for proper use are imprinted on the cap cover. A vacuum safety relief valve is incorporated into this cap.

The modular fuel sender assembly mounts to the threaded opening of the plastic fuel tank with a seal and a retainer ring. The reservoir, containing the exterior inlet strainer, the electric fuel pump and the pump strainer, maintains contact with the tank bottom. This design provides

1. Optimum fuel level in the integral fuel reservoir during all fuel tank levels and during driving conditions
2. An improved tank fuel level measuring accuracy
3. An improved coarse straining and added pump inlet filtering
4. More extensive internal fuel pump isolation for noiseless operation

The modular fuel sender assembly maintains an optimum fuel level in the reservoir (bucket). The fuel entering the reservoir is drawn in by the following components

1. The first stage of the fuel pump through the external strainer and/or
2. The secondary umbrella valve or
3. The return fuel line, whenever the level of fuel is below the top of the reservoir

The electric fuel pump is a turbine pump which is located inside of the modular fuel sender. The electric fuel pump operation is controlled by the engine control module (ECM) through the fuel pump relay.

The strainers act as a coarse filter to perform the following functions

1. Filter contaminants
2. Separate water from fuel
3. Provide a wicking action that helps draw fuel into the fuel pump

Fuel stoppage at the strainer indicates that the fuel tank contains an abnormal amount of sediment or water. Therefore, the fuel tank will need to be removed and cleaned, and the filter strainer should be replaced.

The fuel filter is located on the fuel feed pipe, between the fuel pump and the fuel rail. The electric fuel pump supplies fuel through the in-line fuel filter to the fuel injection system. The fuel pressure regulator keeps the fuel available to the fuel injectors at a regulated pressure. Unused fuel is returned from the fuel filter to the fuel tank by a separate fuel return pipe. 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.

The EVAP line extends from the fuel tank vent valve to the EVAP canister and into the engine compartment. The EVAP line is made of nylon and connects to the EVAP canister with a quick connect fitting.

The fuel pressure regulator attaches to the fuel return pipe on the fuel sender assembly. The fuel pressure regulator is a diaphragm-operated relief valve. A software bias compensates the injector on-time because the fuel pressure regulator is not referenced to manifold vacuum. The injector pulse width varies with the signal from the mass air flow (MAF)/intake air temperature (IAT) sensor.

With the engine running at idle, the system fuel pressure at the pressure test connection should be between 380-410 kPa (55-60 psi). With the system pressurized and the pump OFF the pressure should stabilize and hold. If the pressure regulator supplies a fuel pressure which is too low or too high, a driveability condition will result.

The fuel rail consists of 3 parts

1. The pipe that carries fuel to each injector
2. The fuel pressure test port
3. Eight individual fuel injectors

The fuel rail is mounted on the intake manifold and distributes the fuel to each cylinder through the individual injectors.

The fuel injector is a solenoid device that is controlled by the ECM. When the ECM energizes the injector coil, a normally closed ball valve opens, allowing the fuel to flow past a director plate to the injector outlet. The director plate has holes that control the fuel flow, generating a dual conical spray pattern of finely atomized fuel at the injector outlet. The fuel from the outlet is directed at both of the intake valves, causing the fuel to become further vaporized before entering the combustion chamber.

The fuel injectors will cause various driveability conditions if the following conditions occur

1. If the injectors will not open
2. If the injectors are stuck open
3. If the injectors are leaking
4. If the injectors have a low coil resistance

Fuel Pump Relay

The fuel pump relay allows the ECM to energize the fuel pump. The ECM enables the fuel pump whenever the crankshaft position (CKP) sensor pulses are detected.

The engine is fueled by individual injectors, one for each cylinder, that are controlled by the ECM. The ECM controls each injector by energizing the injector coil for a brief period once every other engine revolution. The length of this brief period, or pulse, is carefully calculated by the ECM to deliver the correct amount of fuel for proper driveability and emissions control. The period of time when the injector is energized is called the pulse width and is measured in milliseconds, thousandths of a second.

While the engine is running, the ECM is constantly monitoring the inputs and recalculating the appropriate pulse width for each injector. The pulse width calculation is based on the injector flow rate, mass of fuel the energized injector will pass per unit of time, the desired air/fuel ratio, and actual air mass in each cylinder and is adjusted for battery voltage, short term, and long term fuel trim. The calculated pulse is timed to occur as each cylinders intake valves are closing to attain largest duration and most vaporization.

Fueling during a crank is slightly different than fueling during an engine run. As the engine begins to turn, a prime pulse may be injected to speed starting. As soon as the ECM can determine where in the firing order the engine is, the ECM begins pulsing the injectors. The pulse width during the crank is based on the coolant temperature and the engine load.

The fueling system has several automatic adjustments in order to compensate for the differences in the fuel system hardware, the driving conditions, the fuel used, and the vehicle aging. The basis for the fuel control is the pulse width calculation that is described above. Included in this calculation are an adjustment for the battery voltage, the short term fuel trim, and the long term fuel trim. The battery voltage adjustment is necessary since the changes in the voltage across the injector affect the injector flow rate. The short term and the long term fuel trims are fine and gross adjustments to the pulse width that are designed in order to maximize the driveability and emissions control. These fuel trims are based on the feedback from the oxygen sensors in the exhaust stream and are only used when the fuel control system is in a Closed Loop operation.

Under certain conditions, the fueling system will turn OFF the injectors for a period of time. This is referred to as fuel shut-off. Fuel shut-off is used in order to improve traction, save fuel, improve emissions, and protect the vehicle under certain extreme or abusive conditions.

In case of a major internal problem, the ECM may be able to use a back-up fuel strategy for limp in mode that will run the engine until service can be performed.

The ECM controls the fuel injectors based on information that the ECM receives from several information sensors. Each injector is fired individually in the engine firing order, which is called sequential fuel injection. This allows precise fuel metering to each cylinder and improves the driveability under all of the driving conditions.

The ECM has several operating modes for fuel control, depending on the information that has been received from the sensors.

When the ECM detects reference pulses from the CKP sensor, the ECM will enable the fuel pump. The fuel pump runs and builds up pressure in the fuel system. The ECM then monitors the MAF, IAT, engine coolant temperature (ECT), and the throttle position (TP) sensor signal in order to determine the required injector pulse width for starting.

If the engine is flooded with fuel during starting and will not start, the Clear Flood Mode can be manually selected. To select Clear Flood Mode, push the accelerator to wide open throttle (WOT). With this signal, the ECM will completely turn OFF the injectors and will maintain this stage as long as the ECM indicates a WOT condition with engine speed below 1,000 RPM.

The Run Mode has 2 conditions: Open Loop operation and Closed Loop operation. When the engine is first started and the engine speed is above 480 RPM, the system goes into Open Loop operation. In Open Loop operation, the ECM ignores the signals from the oxygen sensors and calculates the required injector pulse width based primarily on inputs from the MAF, IAT and ECT sensors.

In Closed Loop, the ECM adjusts the calculated injector pulse width for each bank of injectors based on the signals from each oxygen sensor.

The ECM monitors the changes in the TP and the MAF sensor signals in order to determine when the vehicle is being accelerated. The ECM will then increase the injector pulse width in order to provide more fuel for improved performance.

The ECM monitors changes in TP and MAF sensor signals to determine when the vehicle is being decelerated. The ECM will then decrease injector pulse width or even shut OFF injectors for short periods to reduce exhaust emissions, and for better (engine braking) deceleration.

The ECM can compensate in order to maintain acceptable vehicle driveability when the ECM sees a low battery voltage condition. The ECM compensates by performing the following functions

1. Increasing the injector pulse width in order to maintain the proper amount of fuel being delivered
2. Increasing the idle speed to increase the generator output

The ECM has the ability to completely turn OFF all of the injectors or selectively turn OFF some of the injectors when certain conditions are met. These fuel shut-off modes allow the ECM to protect the engine from damage and also to improve the vehicles driveability.

The ECM will disable all of the six injectors under the following conditions

1. Ignition OFF-Prevents engine run-on
2. Ignition ON but no CKP signal-Prevents flooding or backfiring
3. A high engine speed-Above the red line
4. A high vehicle speed-Above the rated tire speed
5. Closed throttle cast down-Reduces the emissions and increases engine braking.

The ECM will selectively disable the injectors under the following conditions

1. The torque management enabled-Transmission shifts or abusive maneuvers.
2. The traction control enabled-In conjunction with the front brakes applying

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 restrictions to the purge path in the evaporative emission (EVAP) system. When the enabling criteria has been met, the control module commands the EVAP vent solenoid valve ON and the EVAP purge solenoid valve ON, allowing 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.

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 control module sends a class 2 message to the driver information center (DIC) illuminating the Check Gas Cap message when a malfunction in the evaporative emission (EVAP) system and a large 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.

Scheme 65

Electronic Ignition (EI) System Operation

The electronic ignition (EI) system produces and controls the high energy secondary spark. This spark ignites the compressed air/fuel mixture at precisely the correct time, providing optimal performance, fuel economy, and control of exhaust emissions. The engine control module (ECM) primarily collects information from the crankshaft position (CKP) and camshaft position (CMP) sensors to control the sequence, dwell, and timing of the spark.

Crankshaft Position (CKP) Sensor

The crankshaft position (CKP) sensor is an internally magnetic biased digital output integrated circuit sensing device. The sensor detects magnetic flux changes of the teeth and slots of the reluctor wheel on the crankshaft. The reluctor wheel is spaced at 60-tooth spacing, with 2 missing teeth for the reference gap. The reference gap is used to identify the crankshaft position at each start-up. The CKP sensor produces an ON/OFF DC voltage of varying frequency, with 58 output pulses per crankshaft revolution. The CKP sensor sends a digital signal to the ECM as each tooth on the reluctor wheel rotates past the CKP sensor. The ECM uses each CKP signal pulse to determine crankshaft speed position. This information is then used to determine the optimum ignition and injection points of the engine. The ECM also uses CKP sensor output information to determine the camshaft relative position to the crankshaft, to control camshaft phasing, and to detect cylinder misfire.

Camshaft Position (CMP) Sensor

The sensor detects magnetic flux changes between the four narrow and wide tooth slots on the reluctor wheel. The CMP sensor provides a digital ON/OFF DC voltage of varying frequency per each camshaft revolution. The ECM will recognize the narrow and wide tooth patterns to identify camshaft position, or which cylinder is in compression and which is in exhaust. The information is then used to determine the correct time and sequence for fuel injection and ignition spark events.

Knock Sensor (KS)

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, also known as spark knock. The KS system uses one or 2 flat response 2-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 dependant upon the level of knock that the KS detects. The control module receives the KS signal through the signal circuit. The KS ground is supplied by the control module through the low reference circuit.

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. A normal KS signal will ride within the noise channel. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal, keeping the signal within the channel. 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 knock is present, the signal will range outside of the noise channel.

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 stay outside of 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. Some diagnostics are also calibrated to detect constant noise from an outside influence such as a loose/damaged component or excessive engine mechanical noise.

Ignition Coils

Each ignition coil has an ignition 1 voltage feed and a ground circuit. The engine control module (ECM) supplies a low reference and an ignition control (IC) circuit. Each ignition coil contains a solid state driver module. The ECM will command the IC circuit ON, which allows the current to flow through the primary coil windings. When the ECM 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.

Engine Misfire Detection

The CKP sensor is used to determine when an engine misfire is occurring. The CMP sensor is used to determine which cylinder is misfiring. By monitoring variations in the crankshaft rotation speed for each cylinder, the ECM is able to detect individual misfire events. For accurate detection of engine misfire, the ECM must distinguish between crankshaft deceleration caused by actual misfire and deceleration caused by rough road conditions. The antilock brake system (ABS) can detect if the vehicle is on a rough road based on wheel acceleration/deceleration data supplied by the wheel speed sensors. If the ABS detects rough road above a predetermined threshold, this information is sent to the ECM. The ECM uses the rough road information when calculating engine misfire. Under certain driving conditions, a misfire rate can be high enough to cause the 3-way catalytic converter (TWC) to overheat damaging the converter. The malfunction indicator lamp (MIL) will flash ON and OFF when converter overheating, damaging conditions are present.

Scheme 66

Scheme 67

Operation

Supercharger boost pressure is regulated to prevent engine and drive train damage. When the engine is operating under high boost conditions, the engine control module (ECM) limits boost pressure to 83 kPa (12 psi). The ECM disables boost under the following conditions

1. Reverse gear is selected.
2. Drivetrain abuse is detected.
3. Electronic throttle control (ETC) fault is detected.
4. Engine coolant temperature (ECT) is greater than 125°C (257°F).
5. An intercooler pump failure is detected.
6. Intake air temperature (IAT) sensor 2 is equal to or greater than 120.5°C (248°F), boost pressure is limited to 145 kPa (7 psi). The ECM commands the boost control solenoid to default to 62 percent DC.
7. Vehicle speeds exceed 159 mph in third, second, and fourth gears only, after 150 seconds boost is trimmed actively.

The ECM controls boost pressure by using the boost control solenoid. The boost control solenoid is normally an open valve. Under most conditions, the ECM commands the boost control solenoid to operate at a 99-100 percent duty cycle. This keeps the solenoid valve closed and allows only inlet vacuum to control the position of the bypass valve. At idle, engine vacuum is applied to the upper side of the bypass valve actuator, counteracting spring tension to hold the bypass valve open. As engine load is increased, engine vacuum is decreased, causing the spring in the bypass valve actuator to overcome the applied vacuum, closing the bypass valve and allowing the boost pressure to increase. The bypass valve starts to close when the vacuum measures 250 mm Hg (10 in Hg) and is fully closed at 90 mm Hg (3.5 in Hg). When reduced boost pressure is desired, the ECM commands the boost control solenoid to operate at a 0 percent duty cycle, but may command a partial duty cycle, approximately 62 percent, depending on the operating condition. This opens the solenoid valve and allows boost pressure to enter the bypass valve actuator at the lower side to counteract the spring tension, opening the bypass valve and re-circulating excess boost pressure back into the supercharger inlet.

Results of Incorrect Operation

The following conditions will result in reduced engine power, especially during a wide open throttle (WOT) operation

1. An open boost control solenoid control circuit.
2. An open control solenoid ignition 1 voltage circuit.
3. An open control solenoid control circuit.
4. A boost control solenoid valve that is stuck open.

The following conditions will result in full boost to be commanded at all times. These conditions can also result in overboost conditions during high engine load situations.

1. A boost control solenoid control circuit shorted to ground.
2. A boost control solenoid valve is stuck closed.
3. A restriction in the boost source or signal vacuum hoses.
4. A restriction in the exhaust system may cause an overboost condition and reduced fuel economy.

A restriction in the vacuum signal hose to the bypass valve actuator or stuck closed bypass valve will cause a noisy idle and reduced fuel economy.

Scheme 68

Intake Manifold/Supercharger Assembly

The LS9 Roots type supercharger is a positive displacement pump that consists of 2 counter-rotating rotors installed into the lower intake manifold housing. The rotors are designed with 4 lobes and a helical twist. The rotors of the supercharger are designed to run at a minimal clearance, not in contact with each other or the housing, and are timed to each other by a pair of precision spur gears which are pressed onto the rotor shafts. The rotors are supported at each end by self-lubricating, non-serviceable bearings. The drive belt pulley is pressed onto the input shaft and is also not serviceable.

The lower supercharger assembly consists of the following components

1. Lower intake manifold housing, to include rotors, gears, bearings, and drive belt pulley
2. Bypass valve
3. Bypass actuator
4. Charged air bypass valve
5. Fuel rail with injectors
6. Throttle body assembly
7. Evaporative emission canister purge valve
8. Inlet pressure sensor

Scheme 69

The cover assembly has an integrated intercooler. Cooling the air enhances the effectiveness of the supercharger. The intercooler uses conventional coolant in a system that is separate from the engine cooling system. The intercooler assembly includes the cover, two charge air coolers/heat exchangers, a water manifold assembly, two service bleed ports, and a variety of sensors to monitor air temperature and pressure. The water manifold, located at the front of cover transfers coolant to the cover via four internal transfer tubes. The transfer tubes and water manifold are sealed with o-rings and press-in-place seals. Coolant enters the inlet port of the water manifold assembly, is directed into and through the two charge air coolers/heat exchangers, and exits back into the water manifold. Coolant then exits the water manifold outlet port returning to the separate cooling system.

The cover/intercooler consists of the following components

1. Water manifold assembly
2. Charge air cooler cover
3. Charge air coolers/heat exchangers
4. Intake air temperature (IAT) sensor
5. Barometric pressure sensor
6. Air outlet pressure sensor
7. Service coolant bleed ports

The supercharger is designed to increase the air pressure and density in the intake manifold. When this air is mixed with the correct amount of fuel the result is more power from the engine. This excess air creates a boost pressure in the intake manifold with a maximum engine boost of 72.4 kPa (10.5 psi). Because the supercharger is a positive displacement pump and is directly driven from the engine drive belt system, boost pressure is available at all driving conditions. When boost is not required in situations such as idle or light throttle cruising, the excess air is routed through an internal bypass passage located between the intake manifold and the supercharger inlet. The bypass circuit is regulated by a bypass valve which is similar to a throttle plate. Spring force holds the bypass valve in a normally closed position to create boost. The bypass actuator is a vacuum operated valve that is connected to the vacuum signal between the throttle and the supercharger inlet. Vacuum to the actuator pulls the bypass valve open during idle and light load conditions to decrease boost. The charge air bypass valve is a vacuum/electrically operated solenoid valve that is attached to the supercharger housing. The three-way valve which is controlled by the engine control module (ECM) which determines when pressure from the manifold is routed to the bypass actuator. The charge air bypass valve allows pressure from the manifold to open the bypass valve and lower boost pressure during specific driving conditions. The open bypass valve reduces the pumping effort of the supercharger, thereby increasing the fuel efficiency in light load operations.

Illustration Tool Number/Description CH-48027 Digital Pressure Gage J-23738-A Mityvac J-35555 Metal Mityvac CH-48096 EVAP Service Access Port Tool GE-41415-50 Interrupted Thread Fuel Tank Cap Adapter J-26792 HEI Spark Tester J-34730-1A Fuel Pressure Gage J-34730-405 Injector Test Lamp J-35616 GM-Approved Terminal Test Kit J-35616-200 Test Light - Probe Kit J-36850 Transjel Lubricant J-37088-A Fuel Line Disconnect Tool Set J-37287 Fuel Line Shut Off Adapters J-38522 Variable Signal Generator J-39021 Fuel Injector Coil/Balance Tester J-39765-A Fuel Sender Lock Ring Tool J-41413-200 Evaporative Emissions System Tester (EEST) J-41413-300 EVAP Cap and Plug Kit J-41413-306 EVAP Plug J-41413-307 EVAP Plug J-41413-311 EVAP Plug J-41413-SPT High Intensity White Light J-41413-VLV EVAP Service Port Vent Fitting J-41415-40 Fuel Tank Cap Adapter J-43244 Relay Puller Pliers J-44175 Fuel Composition Tester J-44581 Fuel Disconnect Tool J-44602 Injector Test Adapter J-44603 Injector Test Lamp J-45004 Fuel Tank Drain Hose J-45747 Fuel Sending Unit

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

See also:
• Diagnostic System Check - Vehicle
• DTC P0016
• DTC P0153, P0154, P0160, P1153, P2272, P2273, P2A03, or P2A04
• DTC P0601, P0602, P0603, P0604, P0606, P0607, P060D, P062F, or P2610 (Set in ECM)
• DTC P2544
• Front Wheelhouse Liner Replacement (Front Liner)
• Fastener Caution
• Control Module References
• Diagnostic Trouble Code (DTC) List - Vehicle
• Lifting and Jacking the Vehicle
• Cooling System Draining and Filling (Static Fill)
• Upper Intake Manifold Sight Shield Replacement (LS9)
• Heated Oxygen and Oxygen Sensor Caution
• Excessive Force and Oxygen Sensor Caution
• Instrument Panel Insulator Panel Replacement
• Gasoline/Gasoline Vapors Warning
• PROTECTIVE GOGGLES AND GLOVE WARNING
• Electrical Center Identification Views
• Rear Compartment Floor Panel Carpet Replacement (Convertible)
• Driveline Support Assembly Replacement
• Battery Negative Cable Disconnection and Connection (LS7 or LS9)
• Exhaust Muffler Replacement - Left Side
• Transmitter Programming (N. America and Japan, except Canada)
• Transmitter Programming (Canada and Europe)
• Transmitter Programming (New RCDLR ONLY)
• Battery Disconnect Warning
• Adhesives, Fluids, Lubricants, and Sealers (6.2L LS3)
• Adhesives, Fluids, Lubricants, and Sealers (7.0L)
• Fuel and Evaporative Emission Pipe Warning
• Power Steering Pump Replacement (LS3, LS7)
• Supercharger Assemble
• Air Cleaner Assembly Replacement (6.2L)
• Fuel Pressure Relief (Without CH 48027)
• Ignition System Specifications
• Crankshaft Position System Variation Learn