Engine Controls - 4.3L (Introduction): Removal & Installation Chevrolet Silverado 3500

Powertrain Control Module (PCM) Replacement

Service of the powertrain control module (PCM) should consist of either replacement of the PCM, or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the PCM to be replaced, the replacement PCM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM.

Removal Procedure

1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
3. Release the PCM cover mounting tabs.
4. Release the PCM cover from the mounting brackets.
5. Remove the PCM cover.
6. Loosen the PCM electrical connector bolts (2). NOTE: Refer to PCM and ESD Notice in Cautions and Notices. NOTE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector.
7. Disconnect the PCM electrical connectors.
8. Release the spring latch from the PCM.
9. Release the PCM mounting tabs from the PCM.
10. Remove the PCM.

Installation Procedure

1. Install the PCM. Ensure that the mounting tabs are engaged.
2. Secure the spring latch to the PCM.
3. Connect the PCM electrical connectors. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
4. Tighten the PCM electrical connector bolts (2). Tighten: Tighten the bolts to 8 N.m (71 lb in).
5. Install the PCM cover. Ensure the mounting tabs are engaged into the mounting holes in the cover.
6. If a NEW PCM was installed, program the PCM. Refer to «Service Programming System (SPS)»(ref-184120-S18443623862005082200000) in Programming.
7. Perform the crankshaft position (CKP) system variation learn procedure. Refer to «CKP System Variation Learn Procedure»(ref-184141-S02980936992005082200000) .

1. Drain the cooling system to a level below the sensor. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
2. Disconnect the engine coolant temperature (ECT) sensor electrical connector (5).
3. Remove the ECT sensor.

Note. Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage.

Note. Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.

1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent. NOTE: Refer to Fastener Notice in Cautions and Notices.
2. Install the ECT sensor. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
3. Connect the ECT sensor electrical connector (5).
4. Fill the cooling system, if necessary. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.

1. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (4).
2. Loosen the air cleaner outlet duct clamp at the MAF/IAT sensor.
3. Remove the air cleaner outlet duct from the MAF/IAT sensor.
4. Loosen the MAF/IAT sensor clamp at the air cleaner box.
5. Remove the MAF/IAT sensor.

1. Install the MAF/IAT sensor. NOTE: Refer to Fastener Notice in Cautions and Notices.
2. Tighten the MAF/IAT sensor clamp at the air cleaner box. Tighten: Tighten the clamp to 4 N.m (35 lb in).
3. Install the air cleaner outlet duct to the MAF/IAT sensor.
4. Tighten the air cleaner outlet duct clamp at the MAF/IAT sensor. Tighten: Tighten the clamp to 4 N.m (35 lb in).
5. Connect the MAF/IAT sensor electrical connector (4).

1. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (2).
2. Using a slight rocking motion, while pulling straight up, remove the MAP sensor.
3. Inspect the MAP sensor seal for damage, replace the seal, if necessary.

1. Install a NEW MAP sensor seal, if necessary.
2. Install the MAP sensor.
3. Connect the MAP sensor electrical connector (2).

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
2. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Cautions and Notices.
3. Disconnect the heated oxygen sensor (HO2S) electrical connector (1).
4. Remove the bank 1 HO2S (1).

1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Fastener Notice in Cautions and Notices.
2. Install the bank 1 HO2S (1). Tighten: Tighten the sensor to 42 N.m (31 lb ft).
3. Connect the HO2S electrical connector (1).
4. Connect the CPA retainer.
5. Lower the vehicle.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
2. Remove the heated oxygen sensor (HO2S) connector from the crossmember, if equipped with a manual transmission and 2-wheel drive (2WD).
3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Cautions and Notices.
4. Disconnect the HO2S electrical connector from the harness (2).
5. Remove the HO2S connector from the crossmember, if equipped with a automatic transmission and 2WD.
6. Disconnect the CPA retainer.
7. Disconnect the HO2S electrical connector from the harness.
8. Remove the HO2S connector from the crossmember, if equipped with 4-wheel drive (4WD).
9. Disconnect the CPA retainer.
10. Disconnect the HO2S electrical connector from the harness.
11. Remove the bank 2 HO2S (2).

1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Fastener Notice in Cautions and Notices.
2. Install the bank 2 HO2S (2). Tighten: Tighten the sensor to 42 N.m (31 lb ft).
3. Connect the HO2S electrical connector to the harness.
4. Connect the CPA retainer.
5. Install the HO2S connector to the crossmember, if equipped with 4WD.
6. Connect the HO2S electrical connector to the harness.
7. Connect the CPA retainer.
8. Install the HO2S connector to the crossmember, if equipped with a automatic transmission and 2WD.
9. Connect the HO2S electrical connector to the harness (2).
10. Connect the CPA retainer.
11. Install the HO2S connector to the crossmember, if equipped with a manual transmission and 2WD.
12. Lower the vehicle.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
2. Remove the clip securing the heated oxygen sensor (HO2S) to the engine harness.
3. Remove the HO2S from the harness clip.
4. Remove the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Cautions and Notices.
5. Disconnect the HO2S electrical connector.
6. Remove the bank 2 HO2S (1).

1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Fastener Notice in Cautions and Notices.
2. Install the bank 2 HO2S (1). Tighten: Tighten the sensor to 42 N.m (31 lb ft).
3. Connect the HO2S electrical connector.
4. Install the CPA retainer.
5. Install the HO2S from the harness clip.
6. Install the clip securing the HO2S to the engine harness.
7. Lower the vehicle.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
2. Remove the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Cautions and Notices.
3. Disconnect the HO2S electrical connector.
4. Remove the bank 2 HO2S (2).

1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Fastener Notice in Cautions and Notices.
2. Install the bank 2 HO2S (2). Tighten: Tighten the sensor to 42 N.m (31 lb ft).
3. Connect the HO2S electrical connector.
4. Install the CPA retainer.
5. Lower the vehicle.

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .
2. Disconnect the throttle position (TP) sensor electrical connector (1).
3. Remove the TP sensor screws.
4. Remove the TP sensor.

1. Install the TP sensor. Align the TP sensor with the throttle shaft.
2. Install the TP sensor screws. Tighten: Tighten the screws to 2 N.m (18 lb in).
3. Connect the TP sensor electrical connector (1).
4. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .
2. Disconnect the idle air control (IAC) valve electrical connector (2).
3. Remove the IAC valve screws.
4. Remove the IAC valve and O-ring seal.

1. If installing a NEW IAC valve, measure the distance between the IAC valve pintle and the mounting flange. If the distance is more than 28 mm (1.10 in), use finger pressure, and gently push in the pintle.
2. Install a NEW IAC valve O-ring seal.
3. Lubricate the IAC valve O-ring seal with clean engine oil.
4. Install the IAC valve and O-ring seal.
5. If installing the old IAC valve, clean the old thread locking material from the screws.
6. If installing the old IAC valve coat the screw threads with threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent. NOTE: Refer to Fastener Notice in Cautions and Notices.
7. Install the IAC valve screws. Tighten: Tighten the screws to 3 N.m (27 lb in).
8. Connect the IAC valve electrical connector (2).
9. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .
10. Perform the IAC reset procedure: Turn the ignition to the ON position, wait for 5 seconds. Turn the ignition to the OFF position, wait for 10 seconds. Start the engine and check for proper idle speed.

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .
2. Remove the accelerator cable slug from the throttle body pulley.
3. Disconnect the accelerator cable from the accelerator control bracket.
4. Disconnect and remove the accelerator cable from the engine bracket.
5. Remove the driver side knee bolster. Refer to «Knee Bolster Replacement»(ref-184121-S33691865652005082200000) in Instrument Panel, Gages, and Console.
6. Unseat the accelerator cable retainer (3) from the accelerator pedal lever (2).
7. Squeeze the accelerator cable tangs (1) together, and push the cable through the front of dash.
8. Remove the accelerator cable.

1. Install the accelerator cable through the front of dash. Snap the accelerator cable cover tangs (1) through the front of dash.
2. Install the accelerator cable through the slot in the accelerator pedal lever.
3. Seat the accelerator cable retainer (3) into the accelerator pedal lever (2).
4. Install the driver side knee bolster. Refer to «Knee Bolster Replacement»(ref-184121-S33691865652005082200000) in Instrument Panel, Gages, and Console.
5. Connect the accelerator cable to the accelerator control bracket.
6. Connect the accelerator cable to the engine bracket.
7. Install the accelerator cable slug to the throttle body pulley.
8. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .

1. Remove the drive side knee bolster. Refer to «Knee Bolster Replacement»(ref-184121-S33691865652005082200000) in Instrument Panel, Gages, and Console.
2. Unseat the accelerator cable retainer (3) from the accelerator pedal lever (2).
3. Remove the end bushing retaining clips.
4. Remove the end bushings from the pivot shaft.
5. Remove the accelerator pedal.

1. Install the accelerator pedal.
2. Install the end bushings to the pivot shaft.
3. Install the end bushing retaining clips.
4. Install the accelerator cable through the slot in the accelerator pedal lever.
5. Seat the retainer (3) in the accelerator pedal lever (2).
6. Inspect for the following: Complete throttle opening and closing with no binding Proper carpet fit under the accelerator pedal
7. Install the driver side knee bolster. Refer to «Knee Bolster Replacement»(ref-184121-S33691865652005082200000) in Instrument Panel, Gages, and Console.

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .
2. Remove the air cleaner outlet resonator stud.
3. Remove the cruise control cable from the throttle pulley.
4. Remove the cruise control cable from the engine bracket.
5. Remove the accelerator control cable from the accelerator control bracket.
6. Remove the accelerator control cable from the engine bracket.
7. Remove the accelerator control cable slug from the throttle pulley.
8. Remove the accelerator control cable bracket nuts.
9. Remove the accelerator control cable bracket with the cables attached, from the throttle body.
10. Position and secure the bracket and cables out of the way.
11. Disconnect the following electrical connectors: Throttle position (TP) sensor (1) Idle air control (IAC) valve (2)
12. Remove the throttle body studs.
13. Remove the throttle body.
14. Remove and discard the throttle body seal.

1. Install a NEW throttle body seal and the throttle body.
2. Install the throttle body studs. Tighten: Tighten the studs to 9 N.m (80 lb in).
3. Connect the following electrical connectors: TP sensor (1) IAC valve (2)
4. Position the bracket and cables.
5. Install the accelerator control cable bracket with the cables attached, to the throttle body.
6. Install the accelerator control cable bracket nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
7. Install the accelerator control cable slug to the throttle pulley.
8. Install the accelerator control cable to the engine bracket.
9. Install the accelerator control cable to the accelerator control bracket.
10. Install the cruise control cable to the engine bracket.
11. Install the cruise control cable to the throttle pulley.
12. Install the air cleaner outlet resonator stud. Tighten: Tighten the stud to 10 N.m (89 lb in).
13. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .

1. Remove the fuel rail pressure fitting cap.
2. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage.
3. Install the bleed hose on J 34730-1A into an approved container.

1. Remove the bleed hose on the J 34730-1A from the approved container.
2. Remove the shop towel from around the fitting and discard into an approved container.
3. Disconnect the J 34730-1A from the fuel pressure valve.
4. Install the fuel rail pressure fitting cap.

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184141-S38100902152005082200000) . CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury.
2. Using compressed air, blow any debris from around the fittings.
3. Using J 41769 , insert the correct size tool into the female connector, then push inward to release the locking tabs.
4. Pull the fuel line connection apart.
5. Using a clean shop towel, wipe off the male pipe end.
6. Inspect both ends of the fuel line connections 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 fuel line connections together in order to snap the retaining tabs into place.
3. Once installed, pull on both sides of the fuel line connections to ensure that the connection is secure.

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184141-S38100902152005082200000) .
2. Using compressed air, blow any debris from around the fittings.
3. Squeeze the plastic retainer tabs together.
4. Pull the fuel line connection apart.

1. Apply a few drops of clean engine oil to the male pipe end.
2. Push both sides of the fuel line connections together in order to snap the retaining tabs into place.
3. Once installed, pull on both sides of the fuel line connections to ensure that the connection is secure.

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184141-S38100902152005082200000) .
2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
3. Clean the fuel filter connections.
4. Disconnect the fuel lines (1) from the fuel filter.
5. Cap the fuel lines in order to prevent possible fuel system contamination.
6. Slide the fuel filter from the bracket.
7. Inspect the fuel line O-rings for cuts, nicks, swelling, or distortion. Replace the O-rings if necessary.
8. If a restricted fuel filter is found, clean the entire fuel system. Refer to «Fuel System Cleaning»(ref-184141-S41890492232005082200000) .

1. Slide the NEW fuel filter into the bracket.
2. Remove the caps from the fuel lines.
3. Connect the fuel lines (1). Tighten: Tighten the fittings to 25 N.m (18 lb ft).
4. Lower the vehicle.
5. Inspect for fuel leaks using the following procedure: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184141-S38100902152005082200000) .
2. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-184141-S16867262612005082200000) .
3. Remove the fuel tank filler housing to body screws (1) and retainer (2).
4. Remove the fuel tank filler housing to fuel tank fill pipe screws.
5. Remove the fuel tank filler housing.
6. Remove the rear axle vent hose from the clip on the fuel fill pipe bracket.
7. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
8. Remove the fuel tank ground strap bolt (3).
9. Remove the chassis harness ground strap (2) and fuel tank ground strap (4).
10. Loosen the fuel tank fill pipe clamp at the tank.
11. Remove the fuel tank fill pipe from the tank and vehicle.
12. Remove the evaporative emission (EVAP) canister. Refer to «Evaporative Emission (EVAP) Canister Replacement»(ref-184141-S28468175562005082200000) .
13. If necessary, remove the fuel tank shield bolts.
14. Remove the fuel tank shield.
15. Remove the fuel feed/return pipes from the clip on the fuel tank.
16. Disconnect the fuel feed/return pipes from the fuel tank pipes. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184141-S38737368632005082200000) .
17. Cap the fuel and EVAP pipes in order to prevent possible fuel/EVAP system contamination.
18. Place a suitable adjustable jack under the fuel tank.
19. Remove the fuel tank strap bolts. NOTE: Refer to «Fuel Tank Strap Fastener Notice»(ref-184123-S27170260212005082200000) in Cautions and Notices.
20. Remove the fuel tank straps.
21. Lower the fuel tank until the electrical connections are accessible.
22. Disconnect the fuel sending unit and pressure sensor electrical connectors (1).
23. Completely lower the fuel tank.
24. With the aid of an assistant, place the fuel tank in a suitable work area.
25. Disconnect and remove the fuel feed (3) and return (2) pipes from the sending unit and retaining clips.
26. Disconnect and remove the EVAP pipe (1) from the sending unit, roll over valve (3), and retaining clip.
27. If replacing the fuel tank, remove the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184141-S37316022562005082200000) .

1. If the fuel tank was replaced, install the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184141-S37316022562005082200000) .
2. Install and connect the EVAP pipe (1) to the sending unit, roll over valve (3), and retaining clip.
3. Install and connect the fuel feed (3) and return (2) pipes to the sending unit and retaining clips.
4. With the aid of an assistant, place the fuel tank on the jack.
5. Raise the fuel tank until the electrical connections can be made.
6. Connect the fuel sending unit and pressure sensor electrical connectors (1).
7. Install the fuel tank straps. NOTE: Refer to Fastener Notice in Cautions and Notices.
8. Install the fuel tank strap bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
9. Remove the adjustable jack from under the fuel tank.
10. Remove the caps from the fuel and EVAP pipes.
11. Connect the fuel feed/return pipes to the fuel tank pipes. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184141-S38737368632005082200000) .
12. Install the fuel feed/return pipes to the clip on the fuel tank.
13. Install the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement»(ref-184141-S28468175562005082200000) .
14. If necessary, install the fuel tank shield.
15. Install the fuel tank shield bolts. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
16. Install the fuel tank fill pipe to the vehicle and tank.
17. Tighten the fuel tank fill pipe clamp at the tank. Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
18. Install the chassis harness ground strap (2) and fuel tank ground strap (4).
19. Install the fuel tank ground strap bolt (3). Tighten: Tighten the bolt to 9 N.m (80 lb in).
20. Lower the vehicle.
21. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
22. Install the fuel tank filler housing.
23. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten: Tighten the screws to 2.3 N.m (20 lb in).
24. Install the fuel tank filler housing to body screws (1) and retainer (2). Tighten: Tighten the screws to 2.3 N.m (20 lb in).
25. Fill the fuel tank.
26. Inspect the fuel system for leaks using the following procedure: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-184141-S08983981442005082200000) .
2. Using a slight rocking motion, while pulling straight up, remove the fuel tank pressure sensor.

1. Install the fuel pressure sensor.
2. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-184141-S08983981442005082200000) .

1. Remove the fuel sender. Refer to «Fuel Sender Assembly Replacement»(ref-184141-S37316022562005082200000) .
2. Disconnect the fuel pump electrical connector.
3. Remove the fuel level sensor electrical connector retaining clip.
4. Disconnect the fuel level sensor electrical connector.
5. Remove the fuel level sensor retaining clip.
6. Remove the fuel level sensor.

1. Install the fuel level sensor.
2. Install the fuel level sensor retaining clip.
3. Connect the fuel level sensor electrical connector.
4. Install the fuel level sensor electrical connector retaining clip.
5. Connect the fuel pump electrical connector.
6. Install the fuel sender. Refer to «Fuel Sender Assembly Replacement»(ref-184141-S37316022562005082200000) .

1. Remove the fuel tank filler housing to body screws (1) and retainer (2).
2. Partially drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-184141-S16867262612005082200000) .
3. Remove the fuel tank filler housing to fuel tank fill pipe screws.
4. Remove the fuel tank filler housing.
5. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
6. Remove the fuel tank ground strap (3).
7. Remove the chassis harness ground strap (2) and fuel tank ground strap (4).
8. Remove the rear axle vent hose from the clip on the fuel fill pipe bracket.
9. Loosen the fuel tank fill pipe clamp.
10. Remove the fuel fill pipe from the tank and vehicle.
11. Cap the opening on the fuel tank in order to prevent possible fuel system contamination.

1. Remove the cap from the opening on the fuel tank.
2. Install the fuel fill pipe to the vehicle and tank. NOTE: Refer to Fastener Notice in Cautions and Notices.
3. Tighten the fuel tank fill pipe clamp. Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
4. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
5. Install the chassis harness ground strap (2) and fuel tank ground strap (4).
6. Install the fuel tank ground strap (3). Tighten: Tighten the bolt to 9 N.m (80 lb in).
7. Lower the vehicle.
8. Install the fuel tank filler housing.
9. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten: Tighten the screws to 2.3 N.m (20 lb in).
10. Fill the fuel tank, if necessary.
11. Install the fuel tank filler housing to body screws (1) and retainer (2). Tighten: Tighten the screws to 2.3 N.m (20 lb in).
12. Inspect the system for leaks using the following procedure: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-184141-S08983981442005082200000) .
2. Using J 44402 , remove the sending unit lock ring.
3. Remove the sending unit and seal. Discard the seal.
4. Clean the sending unit sealing surfaces.

1. Install a NEW sending unit seal.
2. Install the sending unit.
3. Using J 44402 , install the sending unit lock ring.
4. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-184141-S08983981442005082200000) .

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184141-S38100902152005082200000) .
3. Disconnect the fuel feed/return pipes (4) from the engine compartment pipes (5).
4. Discard the O-ring seals from fuel feed/return pipes.
5. Cap the fuel pipes in order to prevent possible fuel system contamination.
6. Remove the fuel feed/return pipe bracket nuts.
7. Remove the fuel feed/return pipe bracket.
8. Remove the fuel feed/return pipe bolt.
9. Pull straight up on the pipes in order to remove the pipes from the fuel meter body.
10. Remove and discard the following components from the fuel meter body: Fuel seal retainers (1) Upper fuel seals (2) Spacer rings (3) Lower fuel seals (4)

1. Install the following NEW components to the fuel meter body: Lower fuel seals (4) Spacer rings (3) Upper fuel seals (2) Fuel seal retainers (1)
2. Apply a few drops of clean engine oil to the fuel feed/return pipe ends.
3. Install the fuel feed/return pipes to the fuel meter body.
4. Install the fuel feed/return pipe bracket.
5. Install the fuel feed/return pipe bracket nuts. NOTE: Refer to Fastener Notice in Cautions and Notices.
6. Install the fuel feed/return pipe bolt. Tighten: Tighten the bolt to 6 N.m (53 lb in). Tighten the nuts to 3 N.m (27 lb in).
7. Remove the cap from the fuel pipes.
8. Install NEW O-rings on the fuel feed/return pipes.
9. Connect the fuel feed/return pipes (4) to the engine compartment pipes (5). Tighten: Tighten the fittings to 28 N.m (21 lb ft).
10. Test the system for leaks using the following procedure: Turn the ignition ON, with the engine OFF for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
11. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184141-S38100902152005082200000) .
3. Disconnect the fuel feed/return pipes (4) at the engine pipes (5).
4. Disconnect the EVAP pipe (1).
5. Cap the fuel feed/return and EVAP pipes in order to prevent possible fuel/EVAP system contamination.
6. Remove the fuel feed/return pipe bracket nut.
7. Remove the fuel feed/return pipe bracket from the stud.
8. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
9. Remove the fuel feed/return pipe and EVAP pipe clip from the transmission.
10. If equipped with 4-wheel drive (4WD), remove the fuel feed/return and EVAP pipes from the clip on the transfer case.
11. Remove the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement»(ref-184141-S28468175562005082200000) .
12. Disconnect the fuel feed/return pipes at the fuel tank pipes. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184141-S38737368632005082200000) .
13. Cap the fuel tank pipes.
14. Remove the fuel feed/return and EVAP pipe clip nuts.
15. Disconnect the fuel feed/return and EVAP pipe clips
16. Remove the fuel feed/return and EVAP pipe assembly.

1. Install the fuel feed/return and EVAP pipe assembly.
2. Connect the fuel feed/return and EVAP pipe clips
3. Install the fuel feed/return and EVAP pipe clip nuts.
4. Remove the caps from the fuel tank pipes.
5. Connect the fuel feed/return pipes at the fuel tank pipes. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184141-S38737368632005082200000) .
6. Install the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement»(ref-184141-S28468175562005082200000) .
7. If equipped with 4WD, install the fuel feed/return and EVAP pipes to the clip on the transfer case.
8. Install the fuel feed/return pipe and EVAP pipe clip to the transmission.
9. Lower the vehicle.
10. Install the fuel feed/return pipe bracket to the stud. NOTE: Refer to Fastener Notice in Cautions and Notices.
11. Install the fuel feed/return pipe bracket nut. Tighten: Tighten the nut to 25 N.m (18 lb ft).
12. Remove the caps from the fuel feed/return and EVAP pipes.
13. Connect the EVAP pipe (1).
14. Connect the fuel feed/return pipes (4) at the engine pipes (5). Tighten: Tighten the fittings to 28 N.m (21 lb ft).
15. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .
16. Tighten the fuel fill cap.
17. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
18. Inspect for leaks using the following procedure: Turn the ignition ON, with the engine OFF for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-184141-S08983981442005082200000) .
2. Disconnect and remove the fuel feed (3) and return (2) pipes from the sending unit and retaining clips.
3. Cap the fuel feed/return and EVAP pipes in order to prevent possible fuel/EVAP system contamination.

1. Remove the caps from the fuel feed/return and EVAP pipes.
2. Install and connect the fuel feed (3) and return (2) pipes to the sending unit and retaining clips.
3. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-184141-S08983981442005082200000) .

1. Remove the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(ref-184186-S12640805332005082200000) in Engine Mechanical-4.3L.
2. Remove and discard the fuel meter body seal.
3. Before removal, clean the fuel meter body with a spray type engine cleaner, such as GM X-30A, or equivalent, if necessary. Follow the package instructions. Do not soak the fuel meter body in liquid cleaning solvent.
4. Remove the injectors from the lower intake manifold bores. Lightly pull on the injector tube and using a small pocket screwdriver, remove the injector from the manifold.
5. Remove the MFI (multi-port flexible injection) fuel meter body from the MFI bracket

1. Position the fuel tubes of the MFI fuel meter body in the forward position.
2. Install the MFI fuel meter body into the fuel meter body bracket on the lower intake manifold. Push down firmly to lock the fuel meter body into the fuel meter body bracket.
3. Insert the injectors in the following sequence into the correct injector bore in the lower manifold. Number 3 Number 5 Number 1 Number 2 Number 4 Number 6
4. Insure the electrical connectors on the injectors are positioned so that they do not interfere with each other and are pointing towards the center of the intake manifold. Rotate the electrical connectors inboard if necessary.
5. Lubricate the upper intake manifold O-ring on the fuel meter body with clean engine oil.
6. Install the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(ref-184186-S12640805332005082200000) in Engine Mechanical-4.3L.
7. Tighten the fuel fill cap.
8. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
9. Test for fuel leaks using the following procedure: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.

1. Remove the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(ref-184186-S12640805332005082200000) in Engine Mechanical-4.3L.
2. Remove the fuel pressure regulator retaining clip (5).
3. Twist and pull the fuel pressure regulator (6) in order to remove the regulator from the housing using a shop towel to catch any spilled fuel.
4. Remove and discard the regulator seal O-ring (10).
5. Remove and discard the regulator filter (9).
6. Remove and discard the regulator seal O-ring (8).
7. Remove and discard the regulator seal backup ring (7).
8. Cover the fuel pressure regulator housing to prevent contamination from entering the fuel system.

1. Lubricate the NEW O-rings with clean engine oil.
2. Assemble the following NEW parts to the fuel pressure regulator: Backup ring (7) Regulator seal O-ring (8) Regulator (9) Regulator seal O-ring (10)
3. Install the fuel pressure regulator with the vacuum tube pointing down.
4. Install the fuel pressure regulator retainer clip (5).
5. Install the upper manifold. Refer to «Intake Manifold Replacement - Upper»(ref-184186-S12640805332005082200000) in Engine Mechanical-4.3L.
6. Tighten the fuel fill cap.
7. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
8. Inspect for leaks. Turn the ignition ON, for 2 seconds. Turn the ignition OFF, for 10 seconds. Turn the ignition ON. Inspect for fuel leaks.

1. Remove the fuel meter body. Refer to «Fuel Meter Body Assembly Replacement»(ref-184141-S01874895042005082200000) .
2. Remove the injector retainer lock nuts (4) and retainer (2).
3. While pulling the fuel injector downward, push with a small tip punch down between the injector terminals until the injector is removed.

1. Lubricate the NEW injector O-ring seals with clean engine oil.
2. Install the fuel injector (3) into the fuel meter body injector socket. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
3. Install the injector retainer (4) and the injector retainer lock nuts (2). Tighten: Tighten the nuts to 3 N.m (27 lb in).
4. Install the fuel meter body. Refer to «Fuel Meter Body Assembly Replacement»(ref-184141-S01874895042005082200000) .

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .
2. Disconnect the evaporative emission (EVAP) purge pipe.
3. Disconnect the purge solenoid electrical connector (1).
4. Remove the purge solenoid nuts.
5. Remove the engine wiring harness bracket from the stud.
6. Remove the purge solenoid from the intake manifold.

1. Install the purge solenoid to the intake manifold.
2. Install the engine wiring harness bracket to the stud.
3. Install the purge solenoid nuts. Tighten: Tighten the nuts to 12 N.m (106 lb in).
4. Connect the purge solenoid electrical connector (1).
5. Connect the EVAP purge pipe.
6. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
2. Disconnect the evaporative emission (EVAP) canister vent valve electrical connector (1).
3. Remove the EVAP canister vent valve bracket bolt.
4. Remove the EVAP pipe from the clips (1).
5. Disconnect the EVAP vent pipe (4) from the EVAP canister.
6. Remove the EVAP canister vent valve and pipe from the vehicle.
7. If necessary, disconnect the EVAP vent pipe (3) from the EVAP canister vent valve (2).
8. If necessary, detach the EVAP canister vent valve (2) from the bracket.

1. If necessary, attach the EVAP canister vent valve (2) to the bracket.
2. If necessary, connect the EVAP vent pipe (3) to the EVAP canister vent valve (2).
3. Install the EVAP canister vent valve and pipe to the vehicle.
4. Connect the EVAP vent pipe (4) to the EVAP canister.
5. Install the EVAP pipe to the clips (1). NOTE: Refer to Fastener Notice in Cautions and Notices.
6. Install the EVAP canister vent valve bracket bolt. Tighten: Tighten the bolt to 12 N.m (106 lb in).
7. Connect the EVAP canister vent valve electrical connector (1).
8. Lower the vehicle.

1. Disconnect the EVAP pipe at the EVAP canister purge valve.
2. Disconnect the EVAP pipe from the chassis pipe.
3. Remove the EVAP pipe.
4. Cap the EVAP purge valve and the chassis EVAP pipe in order to prevent possible EVAP system contamination.

1. Remove the caps from the EVAP purge valve and the chassis EVAP pipe.
2. Install the EVAP pipe.
3. Connect the EVAP pipe to the chassis pipe.
4. Connect the EVAP pipe to the EVAP canister purge valve.

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-184141-S08983981442005082200000) .
2. Disconnect and remove the EVAP pipe (1) from the sending unit (2), roll over valve (3), and fuel tank clips (6).
3. Cap the sending unit and roll over valve in order to prevent possible EVAP system contamination.

1. Remove the caps from the sending unit and roll over valve.
2. Install the EVAP pipe to the fuel tank.
3. Install and connect the EVAP pipe (1) to the sending unit (2), roll over valve (3), and fuel tank clips (6).
4. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-184141-S08983981442005082200000)

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
2. Disconnect the EVAP purge pipe from the chassis EVAP purge pipe.
3. Disconnect the EVAP purge pipe from the EVAP canister.
4. Remove the EVAP purge pipe from the clip.
5. Cap the EVAP purge pipe and canister in order to prevent possible EVAP system contamination.

1. Remove the caps from the EVAP purge pipe and canister.
2. Connect the EVAP purge pipe to the EVAP canister.
3. Connect the EVAP purge pipe to the chassis EVAP purge pipe.
4. Install the EVAP purge pipe to the clip.
5. Lower the vehicle.

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184141-S38100902152005082200000)
3. Disconnect the fuel feed/return pipes (4) at the engine pipes (5).
4. Disconnect the EVAP pipe (1).
5. Cap the fuel feed/return and EVAP pipes in order to prevent possible fuel/EVAP system contamination.
6. Remove the fuel feed/return pipe bracket nut.
7. Remove the fuel feed/return pipe bracket from the stud.
8. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
9. Remove the fuel feed/return pipe and EVAP pipe clip from the transmission.
10. If equipped with 4-wheel drive (4WD), remove the fuel feed/return and EVAP pipes from the clip on the transfer case.
11. Remove the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement»(ref-184141-S28468175562005082200000) .
12. Disconnect the fuel feed/return pipes at the fuel tank pipes. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184141-S38737368632005082200000) .
13. Cap the fuel tank pipes.
14. Remove the fuel feed/return and EVAP pipe clip nuts.
15. Disconnect the fuel feed/return and EVAP pipe clips.
16. Remove the fuel feed/return and EVAP pipe assembly.

1. Install the fuel feed/return and EVAP pipe assembly.
2. Connect the fuel feed/return and EVAP pipe clips.
3. Install the fuel feed/return and EVAP pipe clip nuts.
4. Remove the caps from the fuel tank pipes.
5. Connect the fuel feed/return pipes at the fuel tank pipes. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184141-S38737368632005082200000) .
6. Install the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement»(ref-184141-S28468175562005082200000) .
7. If equipped with 4WD, install the fuel feed/return and EVAP pipes to the clip on the transfer case.
8. Install the fuel feed/return pipe and EVAP pipe clip to the transmission.
9. Lower the vehicle.
10. Install the fuel feed/return pipe bracket to the stud.
11. Install the fuel feed/return pipe bracket nut.
12. Remove the caps from the fuel feed/return and EVAP pipes.
13. Connect the EVAP pipe (1).
14. Connect the fuel feed/return pipes (4) at the engine pipes (5).
15. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
2. Disconnect the evaporative emission (EVAP) purge pipe from the chassis EVAP purge pipe.
3. Disconnect the fuel tank EVAP pipe from the EVAP canister.
4. Disconnect the EVAP vent valve pipe from the EVAP canister.
5. Remove the EVAP canister bracket bolt.
6. Remove the EVAP canister.
7. Remove the EVAP pipe from the EVAP canister, and retaining clip.
8. Remove the EVAP canister from the bracket.

1. Install the EVAP canister to the bracket.
2. Install the EVAP pipe to the EVAP canister, and retaining clip.
3. Install the EVAP canister. NOTE: Refer to Fastener Notice in Cautions and Notices.
4. Install the EVAP canister bracket bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
5. Connect the EVAP vent valve pipe to the EVAP canister.
6. Connect the fuel tank EVAP pipe to the EVAP canister.
7. Connect the EVAP purge pipe to the chassis EVAP purge pipe.
8. Lower the vehicle.

Note. There are two procedures available to install the distributor. Use Installation Procedure 1 when the crankshaft has NOT been rotated from the original position. Use Installation Procedure 2 when any of the following components are removed: The intake manifold The cylinder head The camshaft The timing chain or sprockets The complete engine If the malfunction indicator lamp (MIL) turns on and DTC P1345 sets after installing the distributor, this indicates an incorrectly installed distributor. Engine damage or distributor damage may occur. Use Procedure 2 in order to install the distributor.

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .
2. Disconnect the following electrical connectors: Camshaft position (CMP) sensor (2) Fuel pump/oil pressure sensor (3)
3. Remove the ignition coil wire from the ignition coil and distributor cap.
4. Remove the spark plug wires from the distributor cap. Twist each spark plug boot 1/2 turn. Pull only on the wire boot in order to remove the wire from the distributor cap.
5. Remove and discard the distributor cap screws.
6. Remove the distributor cap.
7. Using a grease pencil, mark the position of the rotor in relation to the distributor housing (1).
8. Also, mark the distributor housing and the intake manifold.
9. Remove the distributor hold down bolt.
10. Remove the distributor.
11. As the distributor is being removed, watch the rotor move in a counterclockwise direction about 42 degrees.
12. Note the position of the rotor segment.
13. Place a second mark on the base of the distributor (2). This will aid in achieving proper rotor alignment during distributor installation.

Installation Procedure 1

1. If installing a NEW distributor, place 2 marks on the new distributor housing in the same location as the marks on the original housing.
2. Align the rotor with the second mark (2).
3. Install the distributor.
4. Align the hole in the distributor hold-down clamp over the hole in the intake manifold.
5. As the distributor is being installed, observe the rotor moving in a clockwise direction about 42 degrees.
6. Once the distributor is completely seated, the rotor segment should be aligned with the mark on the distributor base (1).
7. Install the distributor hold down bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
8. Install the distributor cap.
9. Install NEW distributor cap screws. Tighten: Tighten the screws to 2.4 N.m (21 lb in).
10. Connect the following electrical connectors: CMP sensor (2) Fuel pump/oil pressure sensor (3)
11. Install the ignition coil wire to the ignition coil and distributor cap.
12. If the malfunction indicator lamp (MIL) is ON after installing the distributor, and diagnostic trouble code (DTC) P1345 is found, the distributor was installed incorrectly. Refer to installation procedure 2.
13. If the MIL is not on, install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .

Installation Procedure 2

1. Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer are aligned with the tabs on the engine front cover and the number 1 piston is at TDC of the compression stroke.
2. Align the white paint mark on the bottom stem of the distributor, with the pre-drilled indent hole in the bottom of the gear (3).
3. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1).
4. Using a long screwdriver, align the oil pump drive shaft to the drive tab of the distributor.
5. Guide the distributor into the engine. Ensure that the spark plug towers are perpendicular to the centerline of the engine.
6. Once the distributor is fully seated, the rotor segment should be aligned with the pointer cast into the distributor base. This pointer may have a 6 cast into it, indicating that the distributor is to be used on a 6 cylinder engine. If the rotor segment does not come within a few degrees of the pointer, the gear mesh between the distributor and the camshaft may be off a tooth or more. If this is the case, repeat the procedure again in order to achieve proper alignment.
7. Install the distributor hold down bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
8. Install the distributor cap.
9. Install NEW distributor cap screws. Tighten: Tighten the screws to 2.4 N.m (21 lb in).
10. Connect the following electrical connectors: CMP sensor (2) Fuel pump/oil pressure sensor (3)
11. Install the ignition coil wire to the ignition coil and distributor cap.
12. If the MIL is ON after installing the distributor, and DTC P1345 is found, the distributor has been installed incorrectly. Repeat installation procedure 2.
13. If the MIL is not on, install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .
2. Remove the ignition coil wire from the ignition coil and distributor cap.
3. Disconnect the following electrical connectors: Ignition coil (1) Ignition coil driver (2)
4. Remove the accelerator cable slug from the throttle lever.
5. Remove the cruise control cable from the throttle lever.
6. Remove the accelerator cable from the engine bracket.
7. Remove the cruise control cable from the engine bracket.
8. Remove the accelerator control cable bracket nuts.
9. Remove the accelerator control cable bracket with cables attached, from the throttle body.
10. Position and secure the bracket and cables out of the way.
11. Remove the accelerator cable bracket nuts and stud.
12. Remove the accelerator cable bracket.
13. Remove the ignition coil bracket studs.
14. Remove the ignition coil and bracket.
15. Remove the ignition coil bolts/nuts.
16. Remove the ignition coil from the brackets.

1. Install the brackets to either side of the ignition coil. NOTE: Refer to Fastener Notice in Cautions and Notices.
2. Install the ignition coil bolts/nuts. Tighten: Tighten the bolts/nuts to 3.5 N.m (31 lb in).
3. Place the ignition coil and bracket into position.
4. Install the ignition coil bracket studs. Tighten: Tighten the studs to 11 N.m (97 lb in).
5. Install the accelerator cable bracket.
6. Install the accelerator cable bracket nuts and stud. Tighten: Tighten the nuts/stud to 12 N.m (106 lb in).
7. Position the bracket and cables.
8. Install the accelerator control cable bracket with cables attached, to the throttle body.
9. Install the accelerator control cable bracket nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
10. Install the accelerator cable to the engine bracket.
11. Install the cruise control cable to the engine bracket.
12. Install the cruise control cable to the throttle lever.
13. Install the accelerator cable slug to the throttle lever.
14. Connect the following electrical connectors: Ignition coil (1) Ignition coil driver (2)
15. Install the ignition coil wire to the ignition coil and distributor cap.
16. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .
2. Disconnect the ignition coil driver electrical connector (3).
3. Remove ignition control module (2) screws.
4. Remove the ignition control module (2) and heat sink (3).

1. Position the ignition control module (2) and heat sink (3). NOTE: Refer to Fastener Notice in Cautions and Notices.
2. Install ignition control module (2) screws. Tighten: Tighten the screws to 3.5 N.m (31 lb in).
3. Connect the ignition coil driver electrical connector (3).
4. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-184141-S27322872682005082200000) .

1. Remove the spark plug wire from the spark plug. Twist the boot 1/2 turn before removing the boot. Pull only on the boot or use a tool designed for this purpose in order to remove the wire from the spark plug.
2. Remove the spark plug wire from the distributor. Twist each spark plug boot 1/2 turn. Pull only on the boot or use a tool designed for this purpose in order to remove the wire from the distributor.
3. Remove the spark plug wire from the wire separators.

Note. If the boot to wire movement has occurred, the boot will give a false visual impression of being fully seated. Ensure that the boots have been properly assembled by pushing sideways on the installed boots. Failure to properly seat the terminal onto the spark plug will lead to wire core erosion and result in an engine misfire or crossfire condition, and possible internal damage to the engine.

1. Install the spark plug wire at the distributor.
2. Install the spark plug wire to each spark plug.
3. Install the wire to the wire separators. IMPORTANT: Wire routing must be kept intact during service and followed exactly when wires have been disconnected or replaced.
4. Inspect the wires for proper installation: Push sideways on each boot in order to inspect the seating. Reinstall any loose boot. Any time the spark plug wire or boot are installed on the spark plug, new dielectric grease needs to be applied inside the boot.

1. Disconnect the spark plug wire from the spark plug. Twist the boot 1/2 turn before removing the boot. Pull only on the boot or use a tool designed for this purpose in order to remove the wire from the spark plug.
2. Loosen the spark plug 1 or 2 turns.
3. Brush or air blast away any dirt from around the spark plug.
4. Remove the spark plug. If removing more than 1 plug, place each plug in a tray marked with the corresponding cylinder number.

1. Ensure that the spark plug washer is positioned correctly.
2. Inspect the spark plug gap. Adjust the gap as needed. Specification: Spark plug gap: 1.524 mm (0.060 in) NOTE: Refer to Fastener Notice in Cautions and Notices.
3. Hand start the spark plug into the corresponding cylinder.
4. Tighten the spark plug. Tighten: For used heads, tighten the plug to 15 N.m (11 lb ft). For new aluminum heads, tighten the plug to 20 N.m (15 lb ft). For new iron heads, tighten the plug to 30 N.m (22 lb ft).

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
2. If equipped, remove the engine shield bolts.
3. Remove the engine shield.
4. Disconnect the CKP sensor electrical connector (5).
5. Remove the CKP sensor bolt.
6. Remove the CKP sensor.

1. If installing the old CKP sensor, install a NEW O-ring seal.
2. Lubricate the O-ring seal with clean engine oil.
3. Install the CKP sensor.
4. Install the CKP sensor bolt. Tighten: Tighten the bolt to 9 N.m (80 lb in).
5. Connect the CKP sensor electrical connector (5).
6. Install the engine shield.
7. Install the engine shield bolts. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
8. Perform the CKP system variation learn procedure. Refer to «CKP System Variation Learn Procedure»(ref-184141-S02980936992005082200000) .

1. Remove the ignition coil wire from the distributor.
2. Remove the spark plug wires from the distributor. Twist the spark plug wire boot 1/2 turn. Pull only on the boot or use a tool designed for this purpose in order to remove the wires from the distributor.
3. Disconnect the camshaft position (CMP) sensor electrical connector (2).
4. Remove the distributor cap screws.
5. Remove the distributor cap.
6. Remove the rotor screws.
7. Remove the rotor.
8. Align the square slot in the reluctor wheel with the CMP sensor.
9. Remove the CMP screws.
10. Remove the CMP sensor.

1. Insert the CMP sensor in the reluctor wheel slot.
2. Install NEW CMP screws. Tighten: Tighten the screws to 2.2 N.m (19 lb in).
3. Install the rotor.
4. Install NEW rotor screws. Tighten: Tighten the screws to 2 N.m (18 lb in).
5. Install the distributor cap.
6. Install NEW distributor cap screws. Tighten: Tighten the screws to 2.4 N.m (21 lb in).
7. Connect the CMP sensor electrical connector (2).
8. Connect the spark plug wires and ignition coil wire to the distributor.

1. Remove the distributor. Refer to «Distributor Replacement»(ref-184141-S03335214162005082200000) .
2. Disconnect the knock sensor electrical connector (1).
3. Remove the knock sensor bolt (1).
4. Remove the knock sensor (2).

1. Install the knock sensor (2). NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
2. Install the knock sensor bolt (1). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
3. Connect the knock sensor electrical connector (1).
4. Install the distributor. Refer to «Distributor Replacement»(ref-184141-S03335214162005082200000) .

1. Loosen the air cleaner outlet resonator clamp at the mass air flow/intake air temperature (MAF/IAT) sensor.
2. Remove the outlet resonator from the MAT/IAT sensor.
3. Loosen the air cleaner cover screws.
4. Remove the air cleaner cover.
5. Remove the air cleaner element.

1. Insert the air cleaner element.
2. Install the air cleaner cover. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
3. Tighten the air cleaner cover screws until snug.
4. Install the outlet resonator to the MAT/IAT sensor.
5. Tighten the air cleaner outlet duct clamp at the MAF/IAT sensor. Tighten: Tighten the clamp to 4 N.m (35 lb in).

1. Loosen the air cleaner outlet resonator clamp at the mass air flow/intake air temperature (MAF/IAT) sensor.
2. Remove the outlet resonator from the MAT/IAT sensor.
3. Disconnect the MAF/IAT sensor electrical connector (4).
4. Remove the air cleaner by pulling upward until the mounting studs are free from the grommets.

1. Install the air cleaner by pressing downward until the grommets are seated.
2. Connect the MAF/IAT sensor electrical connector (4).
3. Install the outlet resonator to the MAT/IAT sensor. NOTE: Refer to Fastener Notice in Cautions and Notices.
4. Tighten the air cleaner outlet duct clamp at the MAF/IAT sensor. Tighten: Tighten the clamp to 4 N.m (35 lb in).

1. Loosen the air cleaner outlet resonator clamp at the mass air flow/intake air temperature (MAF/IAT) sensor.
2. Separate the duct from the MAF/IAT sensor.
3. Remove the air cleaner outlet resonator wing nut.
4. Remove the air cleaner outlet resonator from the throttle body by pivoting the resonator upward until the hinge clip releases from the lip on the throttle body.
5. Remove the air cleaner outlet resonator.

1. Install the air cleaner outlet resonator.
2. Align the hinge clip with the lip on the throttle body. Install the air cleaner outlet resonator to the throttle body by pivoting the resonator downward until the stud is through the hole in the resonator.
3. Install the air cleaner outlet resonator wing nut.
4. Install the air cleaner outlet resonator to the MAF/IAT sensor. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
5. Tighten the air cleaner outlet duct clamp at the MAF/IAT sensor. Tighten: Tighten the clamp to 4 N.m (35 lb in).