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Engine Controls - 8.1L (Introduction): Removal & Installation Chevrolet Silverado 3500

Testing & Diagnostics 53 illustrations ~9594 words

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

IMPORTANTTo prevent internal PCM damage, the ignition switch must be OFF when disconnecting or connecting power to the PCM. Remove any debris from around the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. The replacement PCM must programmed.

Scheme 138

Scheme 138
Scheme 138
  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. If equipped with the Allison transmission regular production option (RPO) M74, remove the engine harness clip from the PCM cover.
  4. Release the PCM cover mounting tabs.
  5. Release the PCM cover from the mounting bracket.
  6. Remove the PCM cover.
  7. Loosen the PCM electrical connector bolts (2).
  8. Disconnect the PCM electrical connectors.
  9. Release the spring latch from the PCM.
  10. Release the PCM mounting tabs from the PCM.
  11. 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.
  4. Tighten the PCM electrical connector bolts (2). Tighten: Tighten the bolts to 8 N.m (71 lb in).
  5. Install the PCM cover.
  6. If equipped with the Allison transmission RPO M74, install the engine harness clip to the PCM cover.
  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. If a NEW PCM was installed, program the PCM. Refer to «Service Programming System (SPS)»(ref-184120-S18443623862005082200000) in Programming.
  9. Perform the crankshaft position (CKP) system variation learn procedure. Refer to «CKP System Variation Learn Procedure»(ref-184137-S16275306732005082200000) .

Scheme 139

Scheme 139: Removal Procedure
Scheme 139: Removal Procedure
  1. Remove the connector position assurance (CPA) retainer (1).
  2. Disconnect the instrument panel (I/P) harness electrical connector (2).
  3. Disconnect the engine wiring harness electrical connector (1).
  4. Remove the throttle actuator control (TAC) module nuts.
  5. Remove the TAC module.
  6. If equipped with a regular production option (RPO) ML6 manual transmission, unsnap the TAC module from the bracket.
  7. If equipped with a RPO ML6 manual transmission, remove the TAC module bracket nuts.
  8. Remove the TAC module bracket, if necessary.
  1. If equipped with a RPO ML6 manual transmission, install the TAC module bracket, if necessary.
  2. Install the TAC module bracket nuts. Tighten: Tighten the nuts to 9 N.m (80 lb in).
  3. If equipped with a RPO ML6 manual transmission, snap the TAC module to the bracket.
  4. Install the TAC module.
  5. Install the TAC module nuts. Tighten: Tighten the nuts to 9 N.m (80 lb in).
  6. Connect the engine wiring harness electrical connector (1).
  7. Connect the I/P harness electrical connector (2).
  8. Install the CPA retainer (1).

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

Scheme 140

Scheme 140: Removal Procedure
Scheme 140: Removal Procedure
  1. Drain the cooling system to a level below the engine coolant temperature (ECT) 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 ECT sensor electrical connector (3).
  3. Remove the ECT sensor electrical connector from the oil fill tube bracket.
  4. Remove the ECT sensor.
  1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent.
  2. Install the ECT sensor. Tighten: Tighten the sensor to 50 N.m (37 lb ft).
  3. Install the ECT sensor electrical connector to the oil fill tube bracket.
  4. Connect the ECT sensor electrical connector (3).
  5. Refill the cooling system. 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.
IMPORTANTUse care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation.
  1. Remove the intake air resonator. Refer to «Intake Air Resonator Replacement»(ref-184137-S05331089022005082200000) .
  2. Disconnect the MAF/IAT sensor electrical connector (3).
  3. Loosen the MAF/IAT clamp.
  4. Remove the MAF/IAT sensor from the air cleaner assembly.
IMPORTANTThe embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine.
  1. Locate the air flow direction arrow (2) on the MAF/IAT sensor.
  2. Install the MAF/IAT sensor to the air cleaner assembly.
  3. Tighten the MAF/IAT clamp. Tighten: Tighten the clamp to 7 N.m (62 lb in).
  4. Connect the MAF/IAT sensor electrical connector (3).
  5. Install the air intake resonator. Refer to «Intake Air Resonator Replacement»(ref-184137-S05331089022005082200000) .
  1. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-184189-S12958489612005082200000) in Engine Mechanical - 8.1L.
  2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1).
  3. Remove the MAP sensor bolt.
  4. Remove the MAP sensor.
  5. Inspect the MAP sensor seal for wear or damage, replace as necessary.
IMPORTANTLubricate the port of the MAP sensor with clean engine oil. Avoid dipping the sensor port directly into the lubricant or using a solid type of lubricant, as they may block the vacuum port signal.
  1. Install the MAP sensor.
  2. Install the MAP sensor bolt. Tighten: Tighten the bolt to 12 N.m (106 lb in).
  3. Connect the MAP sensor electrical connector (1).
  4. Install the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-184189-S12958489612005082200000) in Engine Mechanical - 8.1L.

Note. Refer to Heated Oxygen and Oxygen Sensor Notice in Cautions and Notices.

Scheme 141

Scheme 141: Removal Procedure
Scheme 141: Removal Procedure
  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.
  3. Disconnect the heated oxygen sensor (HO2S) electrical connector (1).
  4. Remove the HO2S (1).
IMPORTANTA special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before reinstallation.
  1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
  2. Install the HO2S (1). Tighten: Tighten the sensor 42 N.m (31 lb ft).
  3. Connect the HO2S electrical connector (1).
  4. Connect the CPA retainer.
  5. Lower the vehicle.

Note. Refer to Heated Oxygen and Oxygen Sensor Notice in Cautions and Notices.

  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.
  3. Disconnect the heated oxygen sensor (HO2S) electrical connector (1).
  4. Remove the HO2S (3).
IMPORTANTA special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation.

Scheme 142

Scheme 142
Scheme 142
  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 HO2S (3). 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.

Note. Refer to Heated Oxygen and Oxygen Sensor Notice in Cautions and Notices.

Scheme 143

Scheme 143: Removal Procedure
Scheme 143: Removal Procedure
  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.
  3. Disconnect the heated oxygen sensor (HO2S) electrical connector.
  4. Remove the HO2S (3).
IMPORTANTA special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation.

Scheme 144

Scheme 144
Scheme 144
  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 HO2S (3). Tighten: Tighten the sensor to 42 N.m (31 lb ft).
  3. Connect the HO2S electrical connector.
  4. Connect the CPA retainer.
  5. Lower the vehicle.

Note. Refer to Heated Oxygen and Oxygen Sensor Notice in Cautions and Notices.

Scheme 145

Scheme 145: Removal Procedure
Scheme 145: Removal Procedure
  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.
  3. Disconnect the heated oxygen sensor (HO2S) electrical connector.
  4. Remove the HO2S (2).
IMPORTANTA special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads will remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation.
  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 HO2S (2). Tighten: Tighten the sensor to 42 N.m (31 lb ft).
  3. Connect the HO2S electrical connector.
  4. Connect the CPA retainer.
  5. Lower the vehicle.
  1. Remove the connector position assurance (CPA) retainer.
  2. Disconnect the accelerator pedal position (APP) sensor electrical connector.
  3. Reposition the carpet to access the lower nut.
  4. Remove the accelerator pedal nuts.
  5. Remove the accelerator pedal assembly.

Scheme 146

Scheme 146: Installation Procedure
Scheme 146: Installation Procedure
  1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Cautions and Notices.
  2. Install the accelerator pedal nuts. Tighten: Tighten the nuts to 20 N.m (15 lb ft).
  3. Reposition the carpet.
  4. Connect the APP sensor electrical connector.
  5. Install the CPA retainer.
  6. Reposition the carpet.
  7. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range.
  8. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT).
  9. Verify that the vehicle meets the following conditions: The vehicle is not in a reduced engine power mode. The ignition is ON. The ignition is OFF.
  10. Inspect the carpet fit under the accelerator pedal.

Note. Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type.

IMPORTANTAn 8 digit part identification number is stamped on the throttle body casting. Refer to this number if servicing, or part replacement is required.

Scheme 147

Scheme 147
Scheme 147

Scheme 148

Scheme 148
Scheme 148
  1. Remove the intake air resonator. Refer to «Intake Air Resonator Replacement»(ref-184137-S05331089022005082200000) .
  2. Disconnect the throttle actuator motor electrical connector (5).
  3. Remove the throttle body nuts.
  4. Remove the throttle body.
  5. Remove and discard the throttle body gasket.
  1. Install a NEW throttle body gasket.
  2. Install the throttle body. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the throttle body nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
  4. Connect the throttle actuator motor electrical connector (5).
  5. Install the intake air resonator. Refer to «Intake Air Resonator Replacement»(ref-184137-S05331089022005082200000) .
  6. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range.
  7. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT).
  8. Verify that the vehicle meets the following conditions: The vehicle is not in a reduced engine power mode. The ignition is ON. The ignition is OFF.
CAUTIONRefer to Gasoline/Gasoline Vapors Caution in Cautions and Notices.
CAUTIONRefer to Fuel Gage Leak Caution in Cautions and Notices.
  1. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-184189-S12958489612005082200000) in Engine Mechanical - 8.1L.
  2. Remove the fuel rail pressure cap.
  3. 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.
  4. 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.
  5. Install the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-184189-S12958489612005082200000) in Engine Mechanical - 8.1L.
  1. Apply a few drops of clean engine oil to the male connection end.
  2. Push both sides of the fittings together in order to snap the retaining tabs into place.
  3. Once installed, pull on both sides of the connection in order to make sure the connection is secure.
  4. If equipped with the 5.3L (L59) engine, install the retainers to the fuel feed and return line to engine quick-connect fittings.
  5. Install the retainer to the fuel feed line quick-connect fitting.
  6. Install 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.
IMPORTANTThere are several types of plastic fuel and evaporative emission (EVAP) quick connect fittings used on this vehicle. The following instructions apply to all types of plastic quick connect fittings except where indicated.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184136-S33630584752005082200000) .
  2. Using compressed air, blow any dirt or debris from around the quick connect fitting.
  3. Squeeze the plastic quick connect fitting release tabs together to disengage the quick connect fitting. (This step applies to Bartholomew style fittings ONLY)
  4. Squeeze where indicated by the arrows on both sides of the plastic ring to disengage the quick connect fitting.
  5. Squeeze where indicated by the arrows on both sides of the plastic ring to disengage the quick connect fitting.
  6. Pull the quick connect fitting connection apart.
  1. Apply a few drops of clean engine oil to the male connection end.
  2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs to snap into place.
  3. Once installed, pull on both sides of the quick-connect fittings in order to make sure the connection is secure.
IMPORTANTClean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.

Scheme 149

Scheme 149
Scheme 149

Scheme 150

Scheme 150
Scheme 150
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184137-S42170646662005082200000) .
  2. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-184137-S19183371182005082200000) .
  3. Remove the fuel tank fill pipe. Refer to «Filler Tube Replacement (Pickup)»(ref-184137-S35340208032005082200000) or «Filler Tube Replacement (Cab/Chassis - Front)»(ref-184137-S19038215402005082200000) or «Filler Tube Replacement (Cab/Chassis - Rear)»(ref-184137-S21559788562005082200000) .
  4. Disconnect the EVAP canister vent solenoid electrical connector.
  5. Remove the EVAP canister vent solenoid from the fuel tank.
  6. If equipped, remove the fuel tank shield bolts.
  7. Remove the fuel tank shield.
  8. Disconnect the fuel feed and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  9. Cap the fuel and EVAP lines in order to prevent possible system contamination.
  10. Place a suitable adjustable jack under the fuel tank.
  11. Remove the fuel tank strap bolts.
  12. Remove the fuel tank straps.
  13. Lower the fuel tank until the electrical connections are accessible.
  14. Disconnect the fuel sending unit and fuel pressure sensor electrical connectors.
  15. Completely lower the fuel tank.
  16. With the aid of an assistant, place the fuel tank in a suitable work area.
  17. If necessary, remove the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184137-S14845045942005082200000) .

Scheme 151

Scheme 151: Installation Procedure
Scheme 151: Installation Procedure
  1. If necessary, install the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184137-S14845045942005082200000) .
  2. With the aid of an assistant, place the fuel tank onto the adjustable jack.
  3. Raise the fuel tank until the electrical connections can be made.
  4. Connect the fuel sending unit and pressure sensor electrical connectors.
  5. Completely raise the fuel tank.
  6. Install the fuel tank straps.
  7. Install the fuel tank strap bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
  8. Remove the adjustable jack from under the fuel tank.
  9. Remove the caps from the fuel and EVAP lines.
  10. Connect the fuel feed and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  11. If necessary, install the fuel tank shield.
  12. Install the fuel tank shield bolts. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
  13. Install the EVAP canister vent solenoid to the fuel tank.
  14. Connect the EVAP canister vent solenoid electrical connector.
  15. Install the fuel tank fill pipe. Refer to «Filler Tube Replacement (Pickup)»(ref-184137-S35340208032005082200000) or «Filler Tube Replacement (Cab/Chassis - Front)»(ref-184137-S19038215402005082200000) or «Filler Tube Replacement (Cab/Chassis - Rear)»(ref-184137-S21559788562005082200000) .
  16. Refill the fuel tank.
  17. Install the fuel cap.
  18. 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) .
  19. Perform the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
IMPORTANTClean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.

Scheme 152

Scheme 152
Scheme 152
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184137-S42170646662005082200000) .
  2. If equipped with a rear auxiliary tank, disconnect the fuel feed and EVAP (evaporative emission ) quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  3. Cap the fuel feed and EVAP pipes in order to prevent possible system contamination.
  4. Loosen the fuel fill pipe clamp (2) at the tank.
  5. Loosen the vent pipe clamp (1) at the tank.
  6. Remove the fuel fill pipe and vent pipe from the tank.
  7. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-184137-S19183371182005082200000) .
  8. Disconnect the fuel sending unit and fuel pressure sensor electrical connectors (1).
  9. Remove the canister vent solenoid (CVS) line from the fuel tank clips.
  10. Disconnect the fuel feed and EVAP quick connect fittings from the sending unit. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  11. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  12. Remove the fuel tank shield bolts.
  13. Remove the fuel tank shield.
  14. Place a suitable adjustable jack under the fuel tank.
  15. Remove the fuel tank strap bolts.
  16. Remove the fuel tank straps.
  17. Lower the fuel tank.
  18. With the aid of an assistant, place the fuel tank in a suitable work area.
  19. Cap the fuel and EVAP pipes in order to prevent possible system contamination.
  20. If necessary, remove the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184137-S14845045942005082200000) .

Scheme 153

Scheme 153: Installation Procedure
Scheme 153: Installation Procedure
  1. If necessary, install the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184137-S14845045942005082200000) .
  2. Remove the caps from the fuel and EVAP pipes.
  3. With the aid of an assistant, place the fuel tank on the jack.
  4. Raise the fuel tank.
  5. Install the fuel tank straps. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  6. Install the fuel tank strap bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
  7. Remove the jack from under the fuel tank.
  8. Install the fuel tank shield.
  9. Install the fuel tank shield bolts. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
  10. Lower the vehicle.
  11. Connect the fuel feed and EVAP quick connect fittings to the sending unit. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  12. Connect the fuel sending unit and fuel pressure sensor electrical connectors (1).
  13. Install the CVS line to the fuel tank clips.
  14. Install the fuel fill pipe and vent pipe to the tank.
  15. Tighten the vent pipe clamp (1) at the tank.
  16. Tighten the fuel fill pipe clamp (2) at the tank. Tighten: Tighten the clamps to 2.5 N.m (22 lb in).
  17. Remove the caps from the fuel feed and EVAP pipes.
  18. If equipped with a rear auxiliary tank, connect the fuel feed and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  19. Refill the fuel tank.
  20. Install the fuel fill cap.
  21. 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) .
  22. Perform the following steps in order to inspect for leaks. Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
IMPORTANTClean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.

Scheme 154

Scheme 154
Scheme 154
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184137-S42170646662005082200000) .
  2. Loosen the fuel fill pipe hose clamp (2) at the tank.
  3. Loosen the fuel vent pipe hose clamp (1) at the tank.
  4. Remove the fuel fill and vent hoses from the tank.
  5. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-184137-S19183371182005082200000) .
  6. Disconnect the fuel tank pressure sensor electrical connector.
  7. Disconnect the fuel feed and EVAP (evaporative emission) quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  8. Cap the fuel/EVAP lines in order to prevent possible system contamination.
  9. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  10. Remove the fuel tank shield bolts.
  11. Remove the fuel tank shield.
  12. Place a suitable adjustable jack under the fuel tank.
  13. Remove the fuel tank strap bolts.
  14. Remove the fuel tank straps.
  15. Lower the fuel tank.
  16. With the aid of an assistant, place the fuel tank in a suitable work area.
  17. If necessary, remove the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184137-S14845045942005082200000) .

Scheme 155

Scheme 155: Installation Procedure
Scheme 155: Installation Procedure
  1. If necessary, install the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184137-S14845045942005082200000) .
  2. With the aid of an assistant, place the fuel tank on the jack.
  3. Raise the fuel tank.
  4. Install the fuel tank straps. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  5. Install the fuel tank strap bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
  6. Remove the jack from under the fuel tank.
  7. Install the fuel tank shield.
  8. Install the fuel tank shield bolts. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
  9. Lower the vehicle.
  10. Remove the caps from the fuel/EVAP lines.
  11. Connect the fuel feed and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  12. Disconnect the fuel tank pressure sensor electrical connector.
  13. Install the fuel fill and vent hoses to the tank.
  14. Tighten the fuel vent pipe hose clamp (1) at the tank.
  15. Tighten the fuel fill pipe hose clamp (2) at the tank. Tighten: Tighten the clamps to 2.5 N.m (22 lb in).
  16. Refill the fuel tank.
  17. Install the fuel fill cap.
  18. 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.
  19. Perform the following steps in order to inspect for leaks. Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.

Scheme 156

Scheme 156: Removal Procedure
Scheme 156: Removal Procedure
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184137-S34389491612005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184137-S27423560502005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184137-S31508324862005082200000) .
  2. Using a slight rocking motion, while pulling straight up, remove the fuel tank pressure sensor (1).
  1. Install the fuel tank pressure sensor (1).
  2. Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184137-S34389491612005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184137-S27423560502005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184137-S31508324862005082200000) .

Scheme 157

Scheme 157: Removal Procedure
Scheme 157: Removal Procedure
  1. Remove the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184137-S14845045942005082200000) .
  2. Disconnect the fuel pump electrical connector.
  3. Remove the fuel lever 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).
  1. Install the fuel level sensor (1).
  2. Install the fuel level sensor retaining clip.
  3. Connect the fuel level sensor electrical connector.
  4. Install the fuel lever sensor electrical connector retaining clip.
  5. Connect the fuel pump electrical connector.
  6. Install the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184137-S14845045942005082200000) .
  1. Remove the fuel tank filler housing to body screws (1) and retainer (2).
  2. If necessary, partially drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-184137-S19183371182005082200000) .
  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 fill pipe ground wire bolt (1).
  7. Remove the fuel tank fill pipe ground wire (3) anti-rotation tab from the frame hole.
  8. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (2).
  9. Remove the rear axle vent hose from the clip on the fuel fill pipe bracket.
  10. Loosen the fuel tank fill pipe clamp (1) at the fuel tank.
  11. Disconnect the recirculation line from the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  12. Remove the fuel tank fill pipe.
  13. Cap the opening on the fuel tank in order to prevent possible system contamination.

Scheme 158

Scheme 158: Installation Procedure
Scheme 158: Installation Procedure
  1. Remove the cap from the opening on the fuel tank.
  2. Install the fuel tank fill pipe.
  3. Connect the recirculation line to the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) . NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  4. Tighten the fuel tank fill pipe clamp (1) at the fuel tank. Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
  5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
  6. Position the fuel tank fill pipe ground wire and chassis harness ground wire (2).
  7. Install the fuel tank fill pipe ground wire (3) anti-rotation tab into the frame hole.
  8. Install the fuel tank fill pipe ground wire bolt (1). Tighten: Tighten the bolt to 9 N.m (80 lb in).
  9. Lower the vehicle.
  10. Install the fuel tank filler housing.
  11. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten: Tighten the screws to 2.3 N.m (20 lb in).
  12. 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).
  1. If equipped with a rear auxiliary tank, disconnect the fuel and evaporative emission (EVAP) quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  2. Cap the fuel feed and EVAP pipes in order to prevent possible system contamination.
  3. Loosen the fuel fill pipe clamp (2) at the tank.
  4. Loosen the vent pipe clamp (1) at the tank.
  5. Remove the fuel fill pipe and vent pipe from the tank.
  6. Cap the fuel and vent openings in the tank in order to prevent possible system contamination.

Scheme 159

Scheme 159: Installation Procedure
Scheme 159: Installation Procedure
  1. Remove the caps from the fuel and vent openings in the tank.
  2. Install the fuel fill pipe and vent pipe to the tank. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  3. Tighten the vent pipe clamp (1) at the tank.
  4. Tighten the fuel fill pipe clamp (2) at the tank. Tighten: Tighten the clamps to 2.5 N.m (22 lb in).
  5. Remove the caps from the fuel feed and EVAP pipes.
  6. If equipped with a rear auxiliary tank, connect the fuel and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  1. Loosen the fuel fill pipe hose clamp (2) at the tank.
  2. Loosen the fuel vent pipe hose clamp (1) at the tank.
  3. Remove the fuel fill and vent hoses from the tank.
  1. Install the fuel fill and vent hoses to the tank.
  2. Tighten the fuel vent pipe hose clamp (1) at the tank. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  3. Tighten the fuel fill pipe hose clamp (2) at the tank. Tighten: Tighten the clamps to 2.5 N.m (22 lb in).
CAUTIONIn order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.
IMPORTANTThe fuel strainer must be in a horizontal position when installing the sending unit is installed in the tank. When installing the sending unit, assure that the fuel strainer does not block full travel of the float arm.
  1. Install a NEW sending unit seal.
  2. Install the sending unit.
  3. Using J 45722 install the sending unit lock ring.
  4. Connect the EVAP line to the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  5. Connect the fuel line to the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  6. Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184137-S34389491612005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184137-S27423560502005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184137-S31508324862005082200000) .
IMPORTANTClean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.

Scheme 160

Scheme 160
Scheme 160

Scheme 161

Scheme 161
Scheme 161
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184136-S33630584752005082200000) .
  2. Disconnect the fuel feed line (1) at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  3. Disconnect the EVAP canister purge tube line (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination.
  5. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  6. Remove the fuel pipe bracket nut.
  7. Remove the fuel pipe bracket from the bellhousing stud.
  8. Remove the heated oxygen sensor (HO2S) sensor connector from the bracket.
  9. Remove the fuel line clip from the bracket on the transmission.
  10. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case.
  11. Remove the clip from the bracket on the frame.
  12. Remove the transfer case harness from the clip bracket.
  13. Thoroughly wash all contaminants from around the EHCU.
  14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM).
  15. Disconnect the brake lines from the brake pressure modulator valve (BPMV).
  16. Remove the bolts (4) attaching the EHCU bracket to the frame (5).
  17. Remove the EHCU (1).
  18. If equipped with 4WD, remove the torsion bar bracket. Refer to «Torsion Bar Replacement»(ref-184214-S16370331862005082200000) in Front Suspension.
  19. Disconnect the fuel and EVAP lines at the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  20. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination.
  21. Remove the fuel and EVAP bundle clip nuts.
  22. Remove the fuel and EVAP bundle.

Scheme 162

Scheme 162: Installation Procedure
Scheme 162: Installation Procedure
  1. Install the fuel and EVAP bundle. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  2. Install the fuel and EVAP bundle clip nuts. Tighten: Tighten the nuts to 12 N.m (106 lb in).
  3. Remove the caps from the fuel and EVAP lines at the fuel tank.
  4. Connect the fuel and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  5. If equipped with 4WD, install the torsion bar bracket. Refer to «Torsion Bar Replacement»(ref-184214-S16370331862005082200000) in Front Suspension.
  6. Install the EHCU (1).
  7. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  8. Connect the brake lines to the BPMV. Tighten: Tighten the fittings to 25 N.m (18 lb ft).
  9. Connect the chassis electrical harness connectors to the EBCM.
  10. Install the transfer case harness to the clip bracket.
  11. Install the clip to the bracket on the frame.
  12. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case.
  13. Install the fuel line clips to the brackets on the transmission.
  14. Install the HO2S sensor connector to the bracket.
  15. Install the fuel pipe bracket to the bellhousing stud.
  16. Install the fuel pipe bracket nut. Tighten: Tighten the nut to 10 N.m (89 lb in).
  17. Lower the vehicle.
  18. Remove the caps from the fuel rail and EVAP line.
  19. Connect the fuel feed line (1) at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  20. Connect the EVAP canister purge tube line (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  21. Install the fuel fill cap.
  22. 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.
  23. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
IMPORTANTClean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184136-S33630584752005082200000) .
  2. Disconnect the fuel feed line (1) at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  3. Disconnect the EVAP canister purge tube line (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  4. Cap the fuel rail in order to avoid possible system contamination.
  5. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  6. Remove the fuel pipe bracket nut.
  7. Remove the fuel pipe bracket from the bellhousing stud.
  8. Remove the fuel line clips from the brackets on the transmission.
  9. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case.
  10. Disconnect the fuel and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  11. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination.
  12. Remove the EVAP line from the clips (2) on the fuel tank.
  13. Disconnect the quick connect fittings from the EVAP canister.
  14. Remove the fuel and EVAP bundle nuts.
  15. Remove the fuel and EVAP bundle.

Scheme 163

Scheme 163: Installation Procedure
Scheme 163: Installation Procedure
  1. Install the fuel and EVAP bundle. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  2. Install the fuel and EVAP bundle nuts. Tighten: Tighten the nuts to 12 N.m (106 lb in).
  3. Connect the quick connect fittings to the EVAP canister.
  4. Install the EVAP line to the clips (2) on the fuel tank.
  5. Remove the caps from the fuel and EVAP lines.
  6. Connect the fuel and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  7. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case.
  8. Install the fuel line clips to the brackets on the transmission.
  9. Install the fuel pipe bracket to the bellhousing stud.
  10. Install the fuel pipe bracket nut. Tighten: Tighten the nut to 10 N.m (89 lb in).
  11. Lower the vehicle.
  12. Remove the caps from the fuel rail.
  13. Connect the EVAP canister purge tube line (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  14. Connect the fuel feed line (1) at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  15. Install the fuel fill cap.
  16. 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.
  17. Perform the following procedure in order to inspect for leaks. Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
IMPORTANTClean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184136-S33630584752005082200000) .
  2. Disconnect the fuel feed and pressure balance lines from the front tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  3. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination.
  4. Disconnect the fuel feed and pressure balance lines from the rear tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  5. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination.
  6. Remove the rear fuel line bundle clip nuts.
  7. Remove the rear fuel line bundle.
  1. Install the rear fuel line bundle.
  2. Install the rear fuel line bundle clip nuts. Tighten: Tighten the nuts to 12 N.m (106 lb in).
  3. Remove the caps from the fuel and balance lines at the fuel tank.
  4. Connect the fuel feed and pressure balance lines to the rear tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  5. Remove the caps from the fuel and balance lines at the fuel tank.
  6. Connect the fuel feed and pressure balance lines to the front tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  7. Install 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. Perform the following procedure in order to inspect for leaks. Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
IMPORTANTClean the fuel feed pipe connection and surrounding area prior to disconnecting the fitting in order to avoid possible fuel system contamination.

Scheme 164

Scheme 164
Scheme 164
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184137-S34389491612005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184137-S27423560502005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184137-S31508324862005082200000) .
  2. Disconnect and remove the fuel feed line (1) from the sending unit and retaining clips. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  3. Cap the fuel feed and evaporative emission (EVAP) openings in order to prevent possible fuel/EVAP system contamination.
  1. Remove the caps from the fuel feed/return, and EVAP lines.
  2. Install and connect the fuel feed (1) line to the sending unit and retaining clips. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  3. Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184137-S34389491612005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184137-S27423560502005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184137-S31508324862005082200000) .
IMPORTANTAn eight digit identification number is located on the fuel rail. Refer to this number if servicing, or part replacement is required.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184137-S42170646662005082200000) .
  2. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-184189-S12958489612005082200000) in Engine Mechanical - 8.1L.
  3. Disconnect the generator electrical connector (2).
  4. Disconnect the evaporative emission (EVAP) canister purge valve electrical connector.
  5. Disconnect the electronic throttle control (ETC) electrical connector (5).
  6. Remove the engine harness bolt and studs.
  7. Reposition the engine harness to the drivers side of the engine compartment.
  8. Identify the fuel injector connectors to their corresponding injectors in order to ensure correct sequential injector firing order after reassembly.
  9. Pull the top portion (2) of the connector up. Do not pull the top portion of the connector past the top of the white portion (1).
  10. Push the tab (1) on the lower side of the connector in order to release the connector from the injector.
  11. Repeat step 12 and step 13 for each injector connector.
  12. Disconnect the fuel feed (1) line from the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  13. Remove the fuel rail studs.
  14. Remove the fuel rail.
  15. Remove and discard the fuel injector lower O-ring seals (4) from the spray tip end of each injector (3).
  1. Lubricate NEW lower injector O-ring seals (4) with clean engine oil.
  2. Install the NEW O-ring seals (4) onto the spray tip end of each injector (3).
  3. Install the fuel rail.
  4. Install the fuel rail studs. Tighten: Tighten the studs to 12 N.m (106 lb in).
  5. Connect the fuel feed (1) line to the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  6. Connect the fuel injector electrical connectors. Install each connector onto the proper injector in order to ensure correct sequential injector firing order. Rotate the injectors as required in order to avoid stretching the wire harness.
  7. Reposition the engine harness.
  8. Install the engine harness bolt and studs. Tighten: Tighten the bolt/studs to 10 N.m (89 lb in).
  9. Connect the ETC electrical connector (5).
  10. Connect the EVAP canister purge valve electrical connector.
  11. Connect the generator electrical connector (2).
  12. Install the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-184189-S12958489612005082200000) in Engine Mechanical - 8.1L.
  13. Install the fuel fill cap.
  14. 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.
  15. Use the following procedure to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.

Scheme 165

Scheme 165: Removal Procedure
Scheme 165: Removal Procedure
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184137-S42170646662005082200000) .
  2. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-184189-S12958489612005082200000) in Engine Mechanical - 8.1L.
  3. Clean any dirt from the fuel pressure dampener retainer and the surrounding area.
  4. Remove the fuel pressure dampener clip (1) and dampener.
  5. Remove the fuel pressure dampener backup ring.
  6. Remove the fuel pressure dampener O-ring.

Scheme 166

Scheme 166: Installation Procedure
Scheme 166: Installation Procedure
  1. Lubricate the fuel pressure dampener O-ring with clean engine oil.
  2. Install the fuel pressure dampener O-ring.
  3. Install the fuel pressure dampener backup ring.
  4. Install the fuel pressure dampener and clip (1).
  5. Install the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-184189-S12958489612005082200000) in Engine Mechanical - 8.1L.
  6. Install 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. Use the following procedure to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.

Note. Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method.

  1. Remove the fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-184137-S18320495502005082200000) .
  2. Remove and discard the fuel injector retaining clip (1).
  3. Remove the injector (5) from the fuel rail.
  4. Remove and discard the injector O-ring seals (2, 4) from both ends of the injector.

Scheme 167

Scheme 167: Installation Procedure
Scheme 167: Installation Procedure
IMPORTANTWhen ordering new fuel injectors, be sure to order the correct injector for the application being serviced.

The fuel injector (1) is stamped with a part number identification (2). A 4-digit build date code (3) indicates the month (4), day (5), year (6), and shift (7) that built the injector.

  1. Lubricate the NEW injector O-ring seals (2, 4) with clean engine oil.
  2. Install the NEW injector O-ring seals onto the injector.
  3. Install a NEW retaining clip (1) on the injector.
  4. Push the fuel injector (5) into the fuel rail with the electrical connector facing outwards. The retaining clip (4) locks onto a flange on the fuel rail injector socket.
  5. Install the fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-184137-S18320495502005082200000) .
IMPORTANTClean the evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  2. Remove the harness clip from the canister vent solenoid (CVS) line.
  3. Disconnect the CVS electrical connector.
  4. If the vehicle is equipped with a 6 ft box, disconnect the EVAP CVS line from the canister.
  5. Remove the CVS clip from the frame crossmember.
  6. Push in the retainer and remove the CVS from the fuel tank clip.
  7. If the vehicle is equipped with a 8 ft box, disconnect the EVAP CVS line from the canister.
  8. Remove the CVS clip from the frame crossmember.
  9. Push in the retainer and remove the CVS from the fuel tank clip.

Scheme 168

Scheme 168: Installation Procedure
Scheme 168: Installation Procedure
  1. If the vehicle is equipped with a 8 ft box, install the CVS to the fuel tank until the clip engages. IMPORTANT: On vehicles equipped with a 8 ft box, the CVS line is routed below the frame crossmember.
  2. Install the CVS clip to the frame crossmember.
  3. Connect the EVAP CVS line to the canister.
  4. If the vehicle is equipped with a 6 ft box, install the CVS to the fuel tank until the clip engages.
  5. Install the CVS clip to the frame crossmember.
  6. Connect the EVAP CVS line to the canister.
  7. Connect the CVS electrical connector.
  8. Install the harness clip to the canister vent solenoid (CVS) line.
  9. Lower the vehicle.
IMPORTANTClean all evaporative emission (EVAP) connections and surrounding areas before disconnecting the line in order to avoid possible EVAP system contamination.

Scheme 169

Scheme 169
Scheme 169
  1. Disconnect the EVAP canister vent solenoid (CVS) electrical connector (1).
  2. Remove the EVAP CVS valve bracket bolt (1).
  3. Remove the EVAP CVS line from the clips on the fuel tank.
  4. Remove the CVS valve and line.
  5. Remove the EVAP CVS valve line from the CVS, if necessary.

Scheme 170

Scheme 170: Installation Procedure
Scheme 170: Installation Procedure
  1. Install the EVAP CVS valve line to the CVS, if necessary.
  2. Install the CVS valve and line. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the EVAP CVS valve bracket bolt (1). Tighten: Tighten the bolt to 12 N.m (106 lb in).
  4. Install the EVAP CVS line to the clips on the fuel tank.
  5. Connect the EVAP CVS electrical connector (1).
  1. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-184189-S12958489612005082200000) in Engine Mechanical - 8.1L.
  2. Disconnect the fuel injector harness electrical connector (3).
  3. Disconnect the evaporative emission (EVAP) purge tube at the purge solenoid.
  4. To disconnect the EVAP purge tube connector (1), slide the retaining tab (2) to the release position and separate the connection.
  5. Disconnect the EVAP purge tube clip from the fuel rail bracket.
  6. Disconnect the EVAP purge tube at the EVAP pipe.

Scheme 171

Scheme 171: Installation Procedure
Scheme 171: Installation Procedure
  1. Connect the EVAP purge tube at the EVAP pipe.
  2. Connect the EVAP purge tube clip to the fuel rail bracket.
  3. Connect the EVAP purge tube at the purge solenoid.
  4. Connect the fuel injector harness electrical connector (3).
  5. Install the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-184189-S12958489612005082200000) in Engine Mechanical - 8.1L.
IMPORTANTClean all the evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel/EVAP system contamination.

Scheme 172

Scheme 172
Scheme 172
  1. Remove the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(ref-184137-S26464400382005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(ref-184137-S10604109862005082200000) .
  2. Remove the EVAP canister line (1). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  3. Remove the EVAP canister purge line (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  4. Cap the fuel and EVAP lines in order to prevent possible fuel/EVAP system contamination.
  1. Remove the caps from the fuel and EVAP lines.
  2. Install the EVAP canister purge line (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  3. Install the EVAP canister line (1). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  4. Install the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(ref-184137-S26464400382005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(ref-184137-S10604109862005082200000) .
IMPORTANTClean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184137-S42170646662005082200000) .
  2. Disconnect the fuel feed line (1) at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  3. Disconnect the EVAP canister purge tube line (2).
  4. Cap the fuel rail in order to avoid possible system contamination.
  5. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  6. Remove the fuel pipe bracket nut.
  7. Remove the fuel pipe bracket from the bellhousing stud.
  8. Remove the fuel line clip from the bracket on the transmission.
  9. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case.
  10. Disconnect the fuel and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  11. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination.
  12. Remove the fuel and EVAP bundle nuts.
  13. Remove the fuel and EVAP bundle.
  1. Install the fuel and EVAP bundle. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  2. Install the fuel and EVAP bundle nuts. Tighten: Tighten the nuts to 12 N.m (106 lb in).
  3. Remove the caps from the fuel and EVAP lines at the fuel tank.
  4. Connect the fuel and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  5. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case.
  6. Install the fuel line clip(s) to the bracket(s) on the transmission.
  7. Install the fuel pipe bracket to the bellhousing stud.
  8. Install the fuel pipe bracket nut. Tighten: Tighten the nut to 10 N.m (89 lb in).
  9. Lower the vehicle.
  10. Remove the cap from the fuel rail.
  11. Connect the fuel feed line (1) at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  12. Connect the EVAP canister purge tube line (2).
  13. Install the fuel fill cap.
  14. 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.
  15. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
IMPORTANTClean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184137-S42170646662005082200000) .
  2. Disconnect the fuel feed and pressure balance lines from the front tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  3. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination.
  4. Disconnect the fuel feed and pressure balance lines from the rear tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  5. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination.
  6. Remove the rear fuel line bundle clip nuts.
  7. Remove the rear fuel line bundle.

Scheme 173

Scheme 173: Installation Procedure
Scheme 173: Installation Procedure
  1. Install the rear fuel line bundle.
  2. Install the rear fuel line bundle clip nuts.
  3. Remove the caps from the fuel and balance lines at the fuel tank.
  4. Connect the fuel feed and pressure balance lines from the rear tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  5. Remove the caps from the fuel and balance lines at the fuel tank.
  6. Connect the fuel feed and pressure balance lines from the front tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  7. Install 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 General Information.
  9. Perform the following procedure in order to inspect for leaks. Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
IMPORTANTClean all evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.

Scheme 174

Scheme 174
Scheme 174
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  2. Disconnect the EVAP canister vent solenoid (CVS) line from the canister.
  3. Disconnect the fuel tank EVAP line from the canister.
  4. Disconnect the canister EVAP line from the fuel bundle line.
  5. Remove the EVAP canister nut.
  6. Remove the EVAP canister with shield from the bracket.
  7. If necessary, remove the EVAP canister from the shield, perform the following: Lift up the retaining clip on the bottom of the canister. Remove the canister from the shield.
  8. If necessary, disconnect the EVAP lines from the canister.
  1. If necessary, connect the EVAP lines to the canister.
  2. If necessary, install the EVAP canister to the shield, perform the following: Install the canister to the shield. Ensure the retaining clip engages on the bottom of the canister. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  3. Install the EVAP canister nut. Tighten: Tighten the nut to 25 N.m (18 lb ft).
  4. Connect the canister EVAP line to the fuel bundle line.
  5. Connect the fuel tank EVAP line to the canister.
  6. Connect the EVAP CVS line to the canister.
  7. Lower the vehicle.
IMPORTANTClean all evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.

Scheme 175

Scheme 175
Scheme 175
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  2. Disconnect the EVAP canister vent solenoid (CVS) line from the canister.
  3. Disconnect the fuel tank EVAP line from the canister.
  4. Disconnect the canister EVAP line from the fuel bundle line.
  5. Remove the EVAP canister nuts.
  6. Remove the EVAP canister.
  1. Install the EVAP canister. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  2. Install the EVAP canister nuts. Tighten: Tighten the nuts to 25 N.m (18 lb ft).
  3. Connect the canister EVAP line to the fuel bundle line.
  4. Connect the fuel tank EVAP line to the canister.
  5. Connect the EVAP CVS line to the canister.
  6. Lower the vehicle.

Note. This component is initially installed using a self-tapping bolt(s). Care should be taken when removing and/or installing the self-tapping bolt(s). Failure to use care when removing and/or installing the self-tapping bolt(s) can lead to damage and unnecessary replacement of the self-tapping bolt(s) and/or the component the self-tapping bolt(s) is threaded into.

Scheme 176

Scheme 176: Installation Procedure
Scheme 176: Installation Procedure
  1. Install ignition coil. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the ignition coil bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
  3. Connect the ignition coil electrical connector.
  4. Connect the spark plug wire to the ignition coil.
  5. Inspect the wire for proper installation: Push sideways on the boot in order to inspect the seating. Reinstall any loose boot.
  1. Install the spark plug wire at the ignition coil.
  2. Install the spark plug wire to the spark plug.
  3. Inspect the wire for proper installation: Push sideways on the boot in order to inspect the seating. Reinstall any loose boot.

Scheme 177

Scheme 177: Spark Plug Inspection
Scheme 177: Spark Plug Inspection
  1. Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to «Ignition System Specifications»(ref-184137-S17809066522005082200000) 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
  3. 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.
  4. 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.
  5. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4).
  6. 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»(ref-184137-S17809066522005082200000) . An excessively wide electrode gap can prevent correct spark plug operation. Inspect for the correct spark plug torque. Refer to «Ignition System Specifications»(ref-184137-S17809066522005082200000) . Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). Inspect for a broken or worn side electrode (3). Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. A loose center electrode (4) reduces the spark intensity. Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. Inspect for excessive fouling.
  7. 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.

Note. In order to prevent damage to the crankshaft position (CKP) sensor reluctor wheel/ring care must be used when removing or installing this component.

Scheme 178

Scheme 178: Removal Procedure
Scheme 178: Removal Procedure
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  2. Remove the fuel line bracket nut.
  3. Remove the fuel line bracket from the bellhousing stud.
  4. Lower the vehicle.
  5. Remove the driver side rear ignition coil bolts.
  6. Reposition the ignition coil.
  7. Disconnect the crankshaft position (CKP) sensor electrical connector (4).
  8. Use penetrating oil and allow the oil to soak around the CKP sensor prior to removing the sensor.
  9. Remove the CKP sensor bolt.
  10. Twist the CKP sensor back and forth.
  11. Pull the sensor straight up in order to remove the CKP sensor.
  12. Inspect the CKP sensor for wear. IMPORTANT: The CKP sensor is designed to contact the reluctor wheel of the crankshaft. Wear may be noticeable on the end of the sensor.
  13. Normal CKP sensor wear will be shown on the wear strips (1) and no wear will be shown on the sensor sensing element (2).
  14. Excessive or abnormal sensor wear will be shown on the sensing element (2).
  15. If excessive/abnormal wear is present, replace the sensor.

Scheme 179

Scheme 179: Installation Procedure
Scheme 179: Installation Procedure
  1. If reusing the old sensor, inspect both O-rings for cuts, cracks, tears or damage, replace the O-rings as needed.
  2. Lubricate the CKP sensor O-rings with clean engine oil. IMPORTANT: Ensure that the CKP sensor is fully seated against the crankshaft reluctor ring. The upper flange on the sensor MAY NOT seat against the engine block.
  3. Install the CKP sensor.
  4. If reusing the old sensor, apply thread adhesive GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the threads.
  5. Install the CKP sensor bolt. Tighten: Tighten the bolt to 12 N.m (106 lb in).
  6. Connect the CKP sensor electrical connector (4).
  7. Position the ignition coil to the rocker cover.
  8. Install the driver side rear ignition coil bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
  9. Raise the vehicle
  10. Install the fuel line bracket to the bellhousing stud.
  11. Install the fuel line bracket nut. Tighten: Tighten the nut to 10 N.m (89 lb in).
  12. Lower the vehicle.
  13. Perform the CKP system variation learn procedure. Refer to «CKP System Variation Learn Procedure»(ref-184137-S16275306732005082200000) .

Scheme 180

Scheme 180: Removal Procedure
Scheme 180: Removal Procedure
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  2. Remove the engine shield bolts and shield, if equipped.
  3. Disconnect the camshaft position (CMP) sensor electrical connector (1).
  4. Remove the CMP sensor bolt.
  5. Remove the CMP sensor.
  6. Inspect the CMP sensor for wear, cracks or leakage if the sensor is not being replaced.
IMPORTANTInspect the CMP sensor O-ring for wear or damage. If a problem is found, replace the O-ring. Lubricate the new O-ring with engine oil before installing.

Scheme 181

Scheme 181
Scheme 181
  1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the CMP sensor bolt. Tighten: Tighten the bolt to 12 N.m (106 lb in).
  3. Connect the CMP sensor electrical connector (1).
  4. Install the engine shield and bolts, if equipped. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  5. Lower the vehicle.

Scheme 182

Scheme 182: Removal Procedure
Scheme 182: Removal Procedure
  1. Drain the cooling system/engine block. 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 knock sensor electrical connector (4).
  3. Remove the knock sensor.
  1. Install the knock sensor. Tighten: Tighten the sensor to 20 N.m (15 lb ft)
  2. Connect the knock sensor electrical connector (4).
  3. Fill the cooling system/engine block. 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.

Scheme 183

Scheme 183: Removal Procedure
Scheme 183: Removal Procedure
  1. Drain the cooling system/engine block. 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 knock sensor electrical connector (3).
  3. Remove the knock sensor.
  1. Install the knock sensor. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
  2. Connect the knock sensor electrical connector (3).
  3. Fill the cooling system/engine block. 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.

Scheme 184

Scheme 184: Removal Procedure
Scheme 184: Removal Procedure
  1. Loosen the air cleaner resonator outlet duct clamp at the mass air flow/intake air temperature (MAF/IAT) sensor.
  2. Loosen the air cleaner resonator outlet duct clamp at the throttle body.
  3. Separate the air cleaner resonator outlet duct from the MAF/IAT sensor.
  4. Separate the air cleaner resonator outlet duct from the throttle body.
  5. Remove the air cleaner resonator outlet duct.

Scheme 185

Scheme 185: Installation Procedure
Scheme 185: Installation Procedure
  1. Install the air cleaner resonator outlet duct.
  2. Install the air cleaner resonator outlet duct to the throttle body.
  3. Align the stud on the throttle body with the screw on the clamp. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Tighten the air cleaner resonator outlet duct clamp at the throttle body. Tighten: Tighten the clamp to 4 N.m (35 lb in).
  5. Install the air cleaner resonator outlet duct to the MAF/IAT sensor.
  6. Tighten the air cleaner resonator outlet duct clamp at the MAF/IAT sensor. Tighten: Tighten the clamp to 4 N.m (35 lb in).

Scheme 186

Scheme 186: Removal Procedure
Scheme 186: Removal Procedure
  1. Remove the intake air resonator. Refer to «Intake Air Resonator Replacement»(ref-184137-S05331089022005082200000) .
  2. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (3).
  3. Loosen the air cleaner housing cover screws.
  4. Remove the air cleaner housing cover.
  5. Remove the air filter element.
  6. Inspect the air filter element for the following: Dust Dirt Water
  7. Clean or replace the air filter element as required.

Scheme 187

Scheme 187: Installation Procedure
Scheme 187: Installation Procedure
  1. Install the air filter element.
  2. Install the air cleaner housing cover.
  3. Tighten the air cleaner housing cover screws until snug.
  4. Connect the MAF/IAT sensor electrical connector (3).
  5. Install the intake air resonator. Refer to «Intake Air Resonator Replacement»(ref-184137-S05331089022005082200000) .
  1. Remove the intake air resonator. Refer to «Intake Air Resonator Replacement»(ref-184137-S05331089022005082200000) .
  2. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (3).
  3. Pull up on the air cleaner assembly (1) in order to release the retainers from the air cleaner adapter (2).
  4. If necessary, loosen the MAF/IAT sensor clamp.
  5. Remove the MAF/IAT sensor.
IMPORTANTIf the MAF/IAT sensor is installed backwards, the fuel system goes rich. An arrow cast into the plastic portion of the sensor indicates proper air flow direction. The arrow must point toward the engine.

Scheme 188

Scheme 188
Scheme 188
  1. If necessary, install the MAF/IAT sensor. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  2. Tighten the MAF/IAT sensor clamp. Tighten: Tighten the clamp to 7 N.m (62 lb in).
  3. Connect the MAF/IAT sensor electrical connector (3).
  4. Install the intake air resonator. Refer to «Intake Air Resonator Replacement»(ref-184137-S05331089022005082200000) .

Scheme 189

Scheme 189: Removal Procedure
Scheme 189: Removal Procedure
  1. Remove the front fender. Refer to «Fender Replacement - Front - Right»(ref-184166-S06955643872005082200000) in Body Front End.
  2. Place the fender in a safe location, in order not to damage it.
  3. Remove the lower intake air duct from the fender.

Scheme 190

Scheme 190: Installation Procedure
Scheme 190: Installation Procedure
  1. Install the lower intake air duct to the fender. Insert the button (2) on the duct (1) into the slot on the fender inner panel extension.
  2. Install the front fender. Refer to «Fender Replacement - Front - Right»(ref-184166-S06955643872005082200000) in Body Front End.

More articles — Engine Controls - 8.1L (Introduction)