Engine Control System - 4.8L, 5.3L, & 6.0L (Introduction): Removal & Installation Chevrolet SSR I

Removal Procedure

1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life.
2. Disconnect negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-187793-S03719997292005090100000) in Engine Electrical.
3. Open the hood
4. Reposition powertrain control module (PCM) water boot aside.
5. Remove PCM from bracket.
6. Disconnect electrical from PCM and remove PCM.

Installation Procedure

1. Install electrical connections to PCM. Tighten: Tighten bolts to 10 N.m (89 lb in).
2. Install the PCM to the bracket.
3. Position PCM water boot back into place.
4. Close the hood.
5. Connect negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-187793-S03719997292005090100000) in Engine Electrical.
6. If the PCM was replaced, the replacement PCM must be programmed. Refer to «Service Programming System (SPS)»(ref-187802-S33411820332005090100000) in Programming.

1. Reposition bulk wiring harness connectors aside.
2. Disconnect the throttle actuator control (TAC) module electrical connectors from the TAC module.
3. Remove nuts retaining TAC module and remove module.

1. Install TAC module and retaining nuts Tighten: Tighten the nuts to 10 N.m (89 lb in).
2. Connect TAC module electrical connectors.
3. Position bulk wiring harness connectors back into place.

1. Turn OFF the ignition.
2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
3. Drain the cooling system below the level of the engine coolant temperature (ECT) sensor. Refer to «Draining and Filling Cooling System»(ref-187839-S38425357962005090100000) in Engine Cooling.
4. Lower the vehicle.
5. Disconnect the ECT sensor electrical connector (1).
6. Remove the ECT sensor.

1. Coat the ECT sensor threads with sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent.
2. Install the ECT sensor. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
3. Connect the ECT sensor electrical connector.
4. Refill the engine coolant. Refer to «Draining and Filling Cooling System»(ref-187839-S38425357962005090100000) in Engine Cooling.

1. Open the hood.
2. Disconnect the electrical connection from mass air flow (MAF)/intake air temperature (IAT) sensor.
3. Remove air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-187797-S41949512502005090100000) .
4. Loosen clamp (2) retaining MAF/IAT to upper air box.
5. Remove MAF/IAT (1) sensor from vehicle.

1. Install the MAF/IAT (1) sensor to upper air box. Tighten: Tighten clamp (2) to 4 N.m (35 lb in).
2. Install the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-187797-S41949512502005090100000) .
3. Connect the electrical connector to MAF/IAT sensor.
4. Close the hood.

1. Loosen the fasteners from the intake manifold sight shield.
2. Remove the sight shield.
3. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
4. Remove the MAP sensor (1) from the intake manifold.

1. Install the MAP sensor (1). Push the MAP sensor down in order to engage the sensor into the retainer.
2. Connect the MAP sensor electrical connector.
3. Install the intake manifold sight shield. Tighten: Tighten the fasteners to 10 N.m (89 lb in).

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Disconnect the connector (1) for the HO2S.
3. Remove the HO2S (2) using a J 39194-B . See «Special Tools and Equipment»(ref-187797-S17483949322005090100000) .

1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary.
2. Install the HO2S (2) using a J 39194-B . See «Special Tools and Equipment»(ref-187797-S17483949322005090100000) . Tighten: Tighten the sensor to 42 N.m (31 lb ft).
3. Connect the HO2S harness connector (1).
4. Lower the vehicle.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Disconnect the connector (1) for the HO2S.
3. Remove the HO2S (2) using a J 39194-B . See «Special Tools and Equipment»(ref-187797-S17483949322005090100000) .

1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary.
2. Install the HO2S (2) using a J 39194-B . See «Special Tools and Equipment»(ref-187797-S17483949322005090100000) . Tighten: Tighten the sensor to 42 N.m (31 lb ft).
3. Connect the HO2S harness connector (1).
4. Lower the vehicle.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Disconnect the connector (1) for the HO2S.
3. Remove the HO2S (2) using a J 39194-B . See «Special Tools and Equipment»(ref-187797-S17483949322005090100000) .

1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary.
2. Install the HO2S (2) using a J 39194-B . See «Special Tools and Equipment»(ref-187797-S17483949322005090100000) . Tighten: Tighten the sensor to 42 N.m (31 lb ft).
3. Connect the HO2S harness connector (1).
4. Lower the vehicle.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Disconnect the connector (1) for the HO2S.
3. Remove the HO2S (2) using a J 39194-B . See «Special Tools and Equipment»(ref-187797-S17483949322005090100000) .

1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary.
2. Install the HO2S (2) using a J 39194-B . See «Special Tools and Equipment»(ref-187797-S17483949322005090100000) . Tighten: Tighten the sensor to 42 N.m (31 lb ft).
3. Connect the HO2S harness connector (1).
4. Lower the vehicle.

Scheme 29

1. Remove the left instrument panel (IP) lower closeout insulator panel.
2. Disconnect the accelerator pedal position (APP) sensor harness connector. Remove the accelerator pedal mounting bolts (1).
3. Remove the APP assembly (2).

1. Install the APP assembly (2) to the steering column support bracket.
2. Install the accelerator pedal mounting bolts (1). Tighten: Tighten the accelerator pedal mounting bolts to 20 N.m (15 lb ft).
3. Connect the APP sensor harness connector.
4. Verify that the vehicle meets the following conditions: The vehicle is not in a Reduced Engine Power mode. The ignition is ON. The engine is OFF.
5. Connect a scan tool in order to test for a proper throttle-opening and throttle-closing range.
6. 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).
7. Inspect the carpet fit under the accelerator pedal.
8. Install the left IP lower closeout insulator panel.

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.

1. Partially drain the cooling system in order to allow the hose at the throttle body to be removed. Refer to «Draining and Filling Cooling System»(ref-187839-S38425357962005090100000) in Engine Cooling.
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-187797-S41949512502005090100000) .
3. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-187833-S04688041382005090100000) in Engine Mechanical-4.8L, 5.3L, and 6.0L.
4. Disconnect the throttle actuator motor electrical connector (3).
5. Reposition the coolant air bleed hose clamp at the throttle body.
6. Remove the coolant air bleed hose from the throttle body.
7. Remove the throttle body nuts.
8. Remove the throttle body and the gasket. IMPORTANT: Do not reuse the throttle body gasket. Install a new gasket during assembly.
9. 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. Install the coolant air bleed hose to the throttle body.
5. Position the coolant air bleed hose clamp at the throttle body.
6. Connect the throttle actuator motor electrical connector (3).
7. Install the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-187833-S04688041382005090100000) in Engine Mechanical-4.8L, 5.3L, and 6.0L.
8. Install the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-187797-S41949512502005090100000) .
9. Refill the cooling system. Refer to «Draining and Filling Cooling System»(ref-187839-S38425357962005090100000) in Engine Cooling.
10. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range.
11. 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).
12. Verify that the vehicle meets the following conditions: The vehicle is not in a reduced engine power mode. The ignition is ON. The engine is OFF.
13. Start the engine.
14. Inspect for coolant leaks.

1. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-187833-S04688041382005090100000) in Engine Mechanical.
2. Install the J 34730-1A to the fuel pressure service connection, located on the fuel rail. See «Special Tools and Equipment»(ref-187797-S17483949322005090100000) .
3. Turn ON the ignition.
4. Place the bleed hose of the fuel pressure gage into an approved gasoline container.
5. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage.
6. Command the fuel pump ON with a scan tool.
7. Close the bleed valve on the fuel pressure gage.
8. Inspect for fuel leaks.

1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure.
2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. See «Special Tools and Equipment»(ref-187797-S17483949322005090100000) .
3. Remove the J 34730-1A from the fuel pressure connection. See «Special Tools and Equipment»(ref-187797-S17483949322005090100000) .
4. Drain any fuel remaining in the fuel pressure gage into an approved container.
5. Inspect for leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
6. Install the cap on the fuel pressure connection.
7. Install the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-187833-S04688041382005090100000) in Engine Mechanical.

1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the «Fuel Pressure Relief Procedure»(ref-187797-S20306617712005090100000) .
2. Remove the retainer from the quick-connect fitting.
3. Blow dirt out of the fitting using compressed air.
4. Choose the correct tool from the J 37088-A tool set for the size of the fitting. See «Special Tools and Equipment»(ref-187797-S17483949322005090100000) . Insert the tool into the female connector, then push inward in order to release the locking tabs.
5. Pull the connection apart.
6. Use a clean shop towel in order to wipe off the male pipe end.
7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required.

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

1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to «Fuel Pressure Relief Procedure»(ref-187797-S20306617712005090100000) .
2. Using compressed air, blow any dirt out of the quick-connect fitting.
3. Squeeze the plastic retainer release tabs.
4. Pull the connection apart.

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

1. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief Procedure»(ref-187797-S20306617712005090100000) .
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
3. Clean all the fuel filter connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
4. Disconnect the quick connect fittings from the fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-187797-S01446972332005090100000) .
5. Cap the fuel pipes in order to prevent possible fuel system contamination.
6. Remove the fuel filter bracket screw (2).
7. Remove the fuel filter (1) from the bracket.

1. Install the fuel filter (1) into the bracket. Ensure that the fuel filter inlet tube is engaged in the fuel tank bracket orientation slot (5).
2. Install the fuel filter bracket screw (2). Ensure that the fuel tank bracket orientation key (4) is engaged in the strap (3) slot. Tighten: Tighten the screw to 1.5 N.m (13 lb in).
3. Remove the caps from the fuel pipes.
4. Connect the quick connect fittings to the fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-187797-S01446972332005090100000) .
5. Lower the vehicle.
6. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-187793-S03719997292005090100000) in Engine Electrical.
7. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
8. Inspect for leaks. Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks. Lower the vehicle.

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-187797-S20306617712005090100000) .
2. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-187797-S18436399132005090100000) .
3. Remove the frame brace. Refer to «Frame Brace Replacement»(ref-187823-S32793909542005090100000) in Frame and Underbody.
4. Loosen the fuel hose clamp (1) at the fuel tank.
5. Separate the fuel hose (2) from the fuel tank.
6. Disconnect the fuel tank pressure sensor electrical connector (3).
7. Disconnect the evaporative emission (EVAP) vent valve electrical connector (2).
8. Disconnect the fuel feed, return and EVAP pipes. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-187797-S01446972332005090100000) .
9. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.
10. Remove propeller shaft. Refer to «Propeller Shaft Replacement»(ref-187850-S27089750152005090100000) in Propeller Shaft.
11. With the aid of an assistant, support the fuel tank.
12. Remove the fuel tank strap bolts (1).
13. Remove the fuel tank straps (2).
14. Carefully lower the fuel tank.
15. Disconnect the fuel sender electrical connector (1).
16. Remove the fuel tank.
17. Place the fuel tank in a suitable work area.
18. If the fuel tank is not being replaced, go to the Installation Procedure.

1. With the aid of an assistant, position and support the fuel tank.
2. Connect the fuel sender electrical connector (1).
3. Install the fuel tank straps (2).
4. Install the fuel tank strap bolts (1). Tighten: Tighten the bolts to 32 N.m (24 lb ft).
5. Install the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-187850-S27089750152005090100000) in Propeller Shaft.
6. Remove the caps from the fuel and EVAP pipes.
7. Connect the fuel feed, return and EVAP pipes. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-187797-S01446972332005090100000) .
8. Connect the fuel tank pressure sensor electrical connector (3).
9. Connect the EVAP vent valve electrical connector (2).
10. Connect the fuel hose (2) to the fuel tank. Tighten: Tighten the clamp (1) to 2.5 N.m (22 lb in).
11. Lower the vehicle.
12. Refill the fuel tank.
13. Install the fuel fill cap.
14. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-187793-S03719997292005090100000) in Engine Electrical.
15. Inspect for leaks. Turn the ignition ON, with the engine OFF for 10 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
16. Install the frame brace. Refer to «Frame Brace Replacement»(ref-187823-S32793909542005090100000) in Frame and Underbody.
17. Lower the vehicle.

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-187797-S00600018942005090100000) .
2. Remove the fuel pressure sensor (1).

1. Install the fuel pressure sensor (1).
2. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-187797-S00600018942005090100000) .

1. Remove the fuel sender assembly. Refer to «Fuel Sender Assembly Replacement»(ref-187797-S28592554922005090100000) .
2. Disconnect the fuel pump electrical connector (5).
3. Remove the retaining clip (6) from the fuel level sensor connector.
4. Disconnect the electrical connector (7) from under the fuel sender cover.
5. Remove the sensor retaining clip (4).
6. Squeeze the locking tangs and remove the fuel level sensor (3).

1. Install the fuel level sensor (3).
2. Install the sensor retaining clip (4).
3. Connect the electrical connector (7) to the fuel level sensor.
4. Connect the retaining clip (6) to the fuel level sensor electrical connector.
5. Connect the fuel pump electrical connector (5).
6. Install the fuel sender assembly. Refer to «Fuel Sender Assembly Replacement»(ref-187797-S28592554922005090100000) .

1. Clean all the fuel pipe and hose connections and the surrounding areas before disconnection in order to avoid possible contamination of the fuel system.
2. Remove the fuel filler cap.
3. Drain the fuel below the level of the fuel filler hose. Refer to «Fuel Tank Draining Procedure»(ref-187797-S18436399132005090100000) .
4. Remove the fuel fill pipe housing to fuel fill pipe bolts.
5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
6. Remove spare tire.
7. Disconnect the fuel fill pipe ground strap (3).
8. Disconnect the rear axle vent hose from the retainer on the fuel fill pipe, if applicable.
9. Loosen the fuel vent hose to fuel tank clamp (1).
10. Loosen the fuel fill hose to fuel tank clamp (11).
11. Disconnect the fuel fill pipe bracket bolt (3).
12. Disconnect the fuel fill and vent hoses from the fuel tank.
13. Remove the fuel fill and vent pipe and hose assembly.
14. Cap the open end of the fuel tank.

1. Uncap the fuel tank.
2. Install the fuel fill and vent pipe hose assembly to the fuel tank. Tighten: Tighten the vent hose clamp (1) and the fuel fill pipe clamp (11) to 2.5 N.m (22 lb in)
3. Install the fuel fill pipe bracket bolt (3). Tighten: Tighten the bolt to 12 N.m (106 lb in).
4. Connect the fuel fill pipe ground strap (3). Tighten: Tighten the fuel fill pipe ground strap bolt to 9 N.m (80 lb in).
5. Connect the rear axle vent hose to the retainer on the fuel fill pipe, if applicable.
6. Install spare tire.
7. Lower the vehicle.
8. Install the fuel fill pipe housing to the fuel fill pipe bolts. Tighten: Tighten the fuel fill pipe housing to fuel fill pipe bolts to 2.3 N.m (20 lb in).
9. Refill the fuel system.
10. Install the fuel filler cap.

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-187797-S00600018942005090100000) .
2. Remove fuel lines from sender assembly. Refer to «Fuel Hose/Pipes Assembly Replacement»(ref-187797-S06387872742005090100000) .
3. Remove the fuel sender assembly retaining ring using the J 44402 . See «Special Tools and Equipment»(ref-187797-S17483949322005090100000) .
4. Remove the fuel sender assembly and the seal. Discard the seal. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container.
5. Clean the fuel sender sealing surfaces.

1. Install the new seal on the fuel tank.
2. Install the fuel sender assembly into the fuel tank. NOTE: Refer to Fastener Notice in Cautions and Notices.
3. Install the fuel sender assembly retaining ring using the J 44402 . See «Special Tools and Equipment»(ref-187797-S17483949322005090100000) .
4. Install fuel lines to sender assembly. Refer to «Fuel Hose/Pipes Assembly Replacement»(ref-187797-S06387872742005090100000) .
5. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-187797-S00600018942005090100000) .

1. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief Procedure»(ref-187797-S20306617712005090100000) .
2. Disconnect the fuel feed and return pipes (1) from the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-187797-S31220176972005090100000) .
3. Cap the fuel rail pipes.
4. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
5. Remove the fuel pipe bracket nut (2).
6. Remove the fuel pipe bracket from the bellhousing stud.
7. Remove the fuel lines from the retaining clips (1) on the transmission.
8. Disconnect the fuel feed and return lines from the rear fuel feed and return lines. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-187797-S01446972332005090100000) .
9. Disconnect the fuel line from the fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-187797-S01446972332005090100000) .
10. Cap the rear fuel lines.
11. Remove the fuel line bundle. IMPORTANT: Note the position of the fuel bundle clips prior to disassembly.
12. Remove the fuel line bundle retaining clips.
13. Remove the fuel feed, return, and/or evaporative emission (EVAP) pipe to be replaced.

1. Install the fuel feed, return, and/or EVAP pipe that was to be replaced.
2. Install the fuel line bundle retaining clips.
3. Install the fuel line bundle.
4. Cap the rear fuel lines.
5. Connect the fuel line to the fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-187797-S01446972332005090100000) .
6. Connect the fuel feed and return lines to the rear fuel feed and return lines. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-187797-S01446972332005090100000) .
7. Install the fuel lines to the retaining clips (1) on the transmission.
8. Install the fuel pipe bracket to the bellhousing stud.
9. Install the fuel pipe bracket nut (2). Tighten: Tighten the nut to 10 N.m (89 lb in).
10. Lower the vehicle.
11. Remove the caps from the fuel rail pipes.
12. Connect the fuel feed and return pipes (1) to the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-187797-S31220176972005090100000) .
13. Install the fuel fill cap.
14. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-187793-S03719997292005090100000) 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.

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-187797-S00600018942005090100000) .
2. Disconnect the fuel return line from the sender assembly. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-187797-S01446972332005090100000) .
3. Disconnect the fuel feed line from the fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-187797-S01446972332005090100000) .
4. Cap the fuel sender assembly pipes.
5. Disengage the fuel lines from the clip (7) at the front of the fuel tank.
6. Remove the fuel lines.

1. Install the fuel lines.
2. Engage the fuel lines to the clip (7) at the front of the fuel tank.
3. Remove the caps from the fuel sender assembly pipes.
4. Connect the fuel feed line to the fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-187797-S01446972332005090100000) .
5. Connect the fuel return line to the sender assembly. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-187797-S01446972332005090100000) .
6. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-187797-S00600018942005090100000) .

1. Clean all the fuel pipe and hose connections and the surrounding areas before disconnecting in order to avoid possible contamination of the fuel system.
2. Drain the fuel below the level of the filler tube and hose assembly. Refer to «Fuel Tank Draining Procedure»(ref-187797-S18436399132005090100000) .
3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
4. Disconnect the fuel fill hose clamp (11) at the fuel tank.
5. Disconnect the fuel fill hose clamp (2) at the fuel fill pipe.
6. Remove the fuel fill hose and the hose clamps (11, 2).
7. Disconnect the fuel fill hose clamp (8) at the fill pipe.
8. Disconnect the fuel fill hose clamp (10) at the fill pipe.
9. Remove the fuel fill hose and the hose clamps (8, 10).
10. Cap the fuel tank opening.

1. Uncap the fuel tank opening.
2. Install the fuel fill hose and the hose clamps (8, 10) to the fuel fill pipe.
3. Install the fuel fill hose and the hose clamps (2, 11) to the fuel fill pipe. NOTE: Refer to Fastener Notice in Cautions and Notices. Tighten: Tighten the hose clamps to 2.5 N.m (22 lb in).
4. Lower the vehicle.
5. Refill the fuel system.

1. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-187833-S04688041382005090100000) in Engine Mechanical.
2. Before removal, clean the fuel rail assembly with a spray type engine cleaner, GM X-30A or equivalent, if necessary. Follow the package instructions. Do not soak fuel rails in liquid cleaning solvent.
3. Disconnect the accelerator control cable and the cruise control cable from the cable bracket.
4. Disconnect the accelerator control cable and the cruise control cable from the throttle body.
5. Remove the upper engine wire harness retainer nut.
6. Disconnect the evaporative emission (EVAP) purge valve harness connector.
7. Reposition the upper engine wire harness aside.
8. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-187797-S20306617712005090100000) .
9. Identify the connectors to their corresponding injectors to ensure correct sequential injector firing order after reassembly.
10. Pull the top portion (2) of the injector connector up. Do not pull the top portion of the connector past the top of the white portion (1).
11. Push the tab (1) on the lower side of the injector connector in order to release the connector from the injector.
12. Repeat step 10 and step 11 for each injector connector.
13. Disconnect the fuel feed and return pipes (1, 2) from the fuel rail.
14. Disconnect the fuel pressure regulator vacuum line.
15. Loosen the crossover tube to right fuel rail retainer screw (22).
16. Remove the fuel rail attaching bolts.
17. Remove the fuel rail assembly.
18. Remove the injector lower O-ring seal (4) from the spray tip end of each injector (3).
19. Discard the O-ring seals.

1. Lubricate the new lower injector O-ring seals (4) with clean engine oil.
2. Install the new O-ring seals (4) on the spray tip end of each injector (3).
3. Remove the crossover tube to the right fuel rail retainer (21).
4. Remove the crossover tube (25) from the right fuel rail (15).
5. Remove the O-ring (20) from the crossover tube (25).
6. Install a new O-ring on the crossover tube.
7. Lubricate the new O-ring with clean engine oil.
8. Install the crossover tube (25) into the right fuel rail (15).
9. Loosely install the crossover tube to the right fuel rail retainer (21).
10. Install the fuel rail assembly to the intake manifold.
11. Apply a 5 mm (0.020 in) band of GM P/N 12345382 (Canadian P/N 10953489) threadlock, or equivalent, to the threads of the fuel rail bolts. NOTE: Refer to the Fastener Notice in Cautions and Notices.
12. Install the fuel rail attaching bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in). Tighten the right crossover pipe retainer screw to 3.8 N.m (34 lb in).
13. Connect the fuel pressure regulator vacuum line.
14. Connect the fuel feed and return pipes (1, 2) to the fuel rail.
15. Connect the injector electrical connectors. Install each connector on 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.
16. Position the upper engine wire harness in place.
17. Connect the EVAP purge solenoid connector.
18. Install the retainer nut to the upper engine wire harness. Tighten: Tighten the nut to 5.5 N.m (49 lb in).
19. Connect the accelerator control cable and the cruise control cable to the cable bracket.
20. Connect the accelerator control cable and the cruise control cable to the throttle body.
21. Install the engine sight shield mounting bracket and the bolts. Refer to «Engine Sight Shield Replacement»(ref-187833-S04688041382005090100000) in Engine Mechanical.
22. Tighten the fuel filler cap.
23. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-187793-S03719997292005090100000) in Engine Electrical.
24. Use the following procedure in order to inspect for leaks: Turn ON the ignition, with the engine OFF, for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
25. Install the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-187833-S04688041382005090100000) in Engine Mechanical.

1. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-187833-S04688041382005090100000) in Engine Mechanical.
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-187797-S20306617712005090100000) .
3. Disconnect the fuel feed pipe (1) and the fuel return pipe (2) from the fuel rail.
4. Remove the fuel return pipe attaching screw (3) and the fuel return pipe retainer (2).
5. Remove the fuel return pipe (1).
6. Remove the fuel return pipe O-ring (6).
7. Remove the fuel pressure connection core assembly (24) from the crossover pipe (25).
8. Remove the retainer clip attaching screw (22) and the crossover fuel pipe to the right fuel rail retainer clip (21).
9. Remove the retainer clip attaching screw (4) and the crossover fuel pipe to the left fuel rail retainer clip (5).
10. Remove the crossover pipe (25) from the left fuel rail (14) and the right fuel rail (15).
11. Remove the crossover fuel pipe O-rings (7, 20).
12. Discard the O-rings (6, 7, 20).

1. Lubricate the new crossover fuel pipe O-rings (7, 20) with clean engine oil.
2. Install the crossover fuel pipe O-rings (7, 20) on the crossover pipe (25).
3. Install the crossover pipe (25) to the left fuel rail (14) and the right fuel rail (15). NOTE: Refer to Fastener Notice in Cautions and Notices.
4. Install the crossover fuel pipe to the right fuel rail retainer clip (21). Loosely install the retainer clip attaching screw (22).
5. Lubricate the new fuel return pipe O-ring (6) with clean engine oil.
6. Install the fuel return pipe O-ring (6) on the fuel return pipe (1).
7. Install the fuel return pipe (1) to the left fuel rail (14).
8. Install the fuel return pipe retainer (2). Loosely install the fuel return pipe attaching screw (3).
9. Install the crossover fuel pipe to left fuel rail retainer clip (5). Loosely install the retainer clip attaching screw (4). Tighten: Tighten the crossover fuel pipe retainer clip attaching screws to 3.8 N.m (34 lb in). Tighten the fuel return pipe attaching screw to 5 N.m (44 lb in).
10. Install the fuel pressure connection core assembly (24) to the crossover pipe (25).
11. Connect the fuel return pipe (2) and the fuel feed pipe (1) to the fuel rail.
12. Tighten the fuel filler cap.
13. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-187793-S03719997292005090100000) in Engine Electrical.
14. Use the following procedure in order to inspect for leaks: Turn ON the ignition, with the engine OFF, for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
15. Install the fuel pressure connection cap.
16. Install the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-187833-S04688041382005090100000) in Engine Mechanical.

1. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-187833-S04688041382005090100000) in Engine Mechanical.
2. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief Procedure»(ref-187797-S20306617712005090100000) .
3. Disconnect the fuel feed pipe (1) and the fuel return pipe (2) from the fuel rail.
4. Remove the fuel return pipe attaching screw (3) and the fuel return pipe retainer (2).
5. Remove the fuel return pipe (1).
6. Remove the fuel return pipe O-ring (6).
7. Discard the O-ring (6).

1. Lubricate the new fuel return pipe O-ring (6) with clean engine oil.
2. Install the fuel return pipe O-ring (6) on the fuel return pipe (1).
3. Install the fuel return pipe (1) to the left fuel rail (14). NOTE: Refer to the Fastener Notice in Cautions and Notices.
4. Install the fuel return pipe retainer (2) and the fuel return pipe attaching screw (3). Tighten: Tighten the fuel return pipe attaching screw (3) to 5 N.m (44 lb in).
5. Connect the fuel return pipe (2) and the fuel feed pipe (1) to the fuel rail.
6. Tighten the fuel filler cap.
7. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-187793-S03719997292005090100000) in Engine Electrical.
8. Use the following procedure in order to inspect for leaks: Turn ON the ignition, with the engine OFF, for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
9. Install the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-187833-S04688041382005090100000) in Engine Mechanical.
10. Install the fuel pressure connection cap.

1. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-187833-S04688041382005090100000) in Engine Mechanical-4.8L, 5.3L, 6.0L.
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-187797-S20306617712005090100000) .
3. Disconnect the fuel pressure regulator vacuum line.
4. Clean any dirt from the fuel pressure regulator retainer and the surrounding area.
5. Remove the fuel pressure regulator retainer (8).
6. Remove the fuel pressure regulator (9) from the fuel pressure regulator housing.

1. Install the backup ring (10) on the fuel pressure regulator (9).
2. Install the new large O-ring (11) on the fuel pressure regulator.
3. Install the regulator filter (12) on the fuel pressure regulator.
4. Install the new small O-ring (13) on the fuel pressure regulator.
5. Lubricate the fuel pressure regulator large O-ring and the small O-ring with clean engine oil.
6. Push the fuel pressure regulator into the regulator housing on the fuel rail.
7. Install a new fuel pressure regulator retainer (8).
8. Connect the fuel pressure regulator vacuum line.
9. Connect the negative battery cable.
10. Tighten the fuel filler cap.
11. Inspect for leaks. Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
12. Install the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-187833-S04688041382005090100000) in Engine Mechanical-4.8L, 5.3L, 6.0L.

1. Remove the fuel rail assembly. Refer to «Fuel Rail Assembly Replacement»(ref-187797-S19860989732005090100000) .
2. Remove the injector retainer clip (19).
3. Remove the injector from the fuel rail pad.
4. Discard the injector retainer clip (1).
5. Remove the injector O-ring seals (2, 4) from both ends of the injector. Discard the O-ring seals.

Scheme 30

The fuel injector assembly (1) is stamped with a part number identification (2). A four-digit build date code (3) indicates the month (4), day (5), year (6), and the 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 on the injector.
3. Install a new retainer clip (1) on the injector.
4. Push the fuel injector (17) into the fuel rail injector socket with the electrical connector facing outward. The retainer clip (19) locks on to a flange on the fuel rail injector socket.
5. Install the fuel rail assembly. Refer to «Fuel Rail Assembly Replacement»(ref-187797-S19860989732005090100000) .

1. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-187833-S04688041382005090100000) in Engine Mechanical.
2. Push the evaporative emission (EVAP) pipe quick connect fitting retainer inward.
3. Disconnect the EVAP pipe (2) from the EVAP purge solenoid (1).
4. Disconnect the EVAP purge solenoid electrical connector.
5. Remove the EVAP purge solenoid mount bolt (2).
6. Remove the EVAP purge solenoid (3) and the insulator (1) from the engine.

1. Install the insulator (1) on the EVAP canister purge valve (3).
2. Install the EVAP canister purge valve (3) to the engine. NOTE: Refer to Fastener Notice in Cautions and Notices.
3. Install the EVAP canister purge valve mount bolt (2). Tighten: Tighten the EVAP canister purge valve mount bolt to 10.5 N.m (93 lb in).
4. Connect the EVAP pipe (2) to the EVAP canister purge valve (1).
5. Connect the EVAP canister purge valve electrical connector.
6. Install the engine sight shield. Refer to «Engine Sight Shield Replacement»(ref-187833-S04688041382005090100000) in Engine Mechanical.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Disconnect the evaporative emission (EVAP) canister vent valve electrical connector (2).
3. Disconnect the EVAP vent pipe from the canister vent valve.
4. Disengage the bracket retaining tab and remove the EVAP canister vent valve.

1. Install the EVAP canister vent valve onto the bracket.
2. Inspect for proper retention of the EVAP vent valve on the bracket.
3. Connect the EVAP vent pipe to the EVAP canister vent valve.
4. Connect the EVAP canister vent valve electrical connector (2).
5. Lower the vehicle.

1. Disconnect the EVAP tube from the EVAP canister purge solenoid. Push the large size white retainer portion in. Push down, while pulling up slightly in order to disengage the tube.
2. Disconnect the EVAP tube from the chassis EVAP pipe. Push the large size white retainer portion in. Push down, while pulling up slightly in order the disengage the tube.
3. Remove the EVAP tube.
4. Cap the EVAP canister purge solenoid and the EVAP chassis pipe in order to prevent possible EVAP system contamination.

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

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-187797-S00600018942005090100000) .
2. Disconnect the evaporative emission (EVAP) canister vent pipe from the canister (3).
3. Disconnect the EVAP canister vent pipe at the EVAP vent valve (1).
4. Cap the EVAP vent valve and canister in order to prevent possible EVAP system contamination.
5. Remove the EVAP canister vent pipe.

1. Install the EVAP canister vent pipe.
2. Remove the caps from the EVAP vent valve and canister.
3. Connect the EVAP canister vent pipe at the EVAP vent valve (1).
4. Connect the EVAP canister vent pipe to the canister (3).
5. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-187797-S00600018942005090100000) .

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-187797-S20306617712005090100000) .
2. Disconnect the fuel feed and return pipes (1) at the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-187797-S31220176972005090100000) .
3. Disconnect the EVAP canister purge pipe (3). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-187797-S01446972332005090100000) .
4. Cap the fuel rail and EVAP pipes in order to prevent possible contamination of the EVAP/fuel system.
5. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
6. Remove the exhaust muffler nuts.
7. Disconnect the catalytic converter from the exhaust muffler.
8. Remove the bolts attaching the transmission crossmember to the frame. Refer to «Transmission Support Replacement»(ref-187823-S11886914312005090100000) in Frame and Underbody.
9. Lower the transmission slightly, only until the catalytic converter almost contacts the crossmember mounting frame bracket.
10. Remove the EVAP/fuel hose/pipe bracket nut (2).
11. Remove the fuel hose/pipe bracket from the bellhousing stud.
12. Remove the EVAP/fuel hose/pipe assembly from the retaining clips (1) on the transmission.
13. Disconnect the fuel return pipe and EVAP pipe from the fuel tank pipes. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-187797-S01446972332005090100000) .
14. Disconnect the fuel feed pipe from the fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-187797-S01446972332005090100000) .
15. Cap the fuel filter and pipes at the fuel tank.
16. Remove the EVAP/fuel hose/pipe assembly from the vehicle.
17. Remove the EVAP/fuel hose/pipe assembly retaining clips.
18. Remove the evaporative emission (EVAP) pipe from the EVAP/fuel hose/pipe assembly.

1. Install the EVAP pipe to the EVAP/fuel hose/pipe assembly.
2. Install the EVAP/fuel hose/pipe assembly retaining clips.
3. Install the EVAP/fuel hose/pipe assembly to the vehicle.
4. Remove the caps from the fuel filter and pipes at the fuel tank.
5. Connect the fuel return pipe and EVAP pipe to the fuel tank pipes. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-187797-S01446972332005090100000) .
6. Connect the fuel feed pipe to the fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-187797-S01446972332005090100000) .
7. Install the EVAP/fuel hose/pipe assembly to the clips (1) on the automatic transmission.
8. Install the EVAP/fuel hose/pipe bracket to the bellhousing stud.
9. Install the EVAP/fuel hose/pipe bracket nut (2). Tighten: Tighten the nut to 10 N.m (89 lb in).
10. Lower the vehicle.
11. Remove the caps from the fuel rail and EVAP pipes.
12. Connect the EVAP canister purge pipe (3).
13. Connect the fuel feed and return pipes (1) at the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-187797-S31220176972005090100000) .
14. Install the fuel fill cap.
15. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-187793-S03719997292005090100000) in Engine Electrical.
16. 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 leaks.

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-187797-S00600018942005090100000) .
2. Disconnect and remove the EVAP pipe from the canister (3).
3. Disconnect and remove the EVAP pipe from the roll over valve (4).
4. Cap the fuel tank roll over valve and canister in order to prevent possible EVAP system contamination.

1. Remove the caps from the fuel tank roll over valve and canister.
2. Install and connect the EVAP pipe to the roll over valve (4).
3. Install and connect the EVAP pipe to the canister (3).
4. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-187797-S00600018942005090100000) .

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-187797-S00600018942005090100000) .
3. Disconnect the evaporative emission (EVAP) vapor pipe (2) from the EVAP canister.
4. Disconnect the EVAP vent pipe (1) from the EVAP canister.
5. Disconnect the EVAP purge pipe from the EVAP canister. The purge pipe is the small pipe next to the vapor pipe (2).
6. Remove the EVAP canister from the tabs of the canister bracket by inserting a flat head screwdriver into the center slots of the tabs as indicated in the illustration.
7. Pry the canister away from the tabs as indicated in the illustration.
8. Slide the canister away from the single tab side to disengage the EVAP canister from the bracket.

1. Slide the EVAP canister into the single tab side and press the canister into the two tab side. Ensure the tabs have completely engaged.
2. Connect the EVAP purge pipe to the EVAP canister. The purge pipe is the small pipe next to the vapor pipe (2).
3. Connect the EVAP vent pipe (1) to the EVAP canister.
4. Connect the EVAP vapor pipe (2) to the EVAP canister.
5. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-187797-S00600018942005090100000) .
6. Lower the vehicle.

1. Disconnect the spark plug wires at the ignition coils.
2. Disconnect the ignition coil harness connector.
3. Remove the ignition coil mounting bolts.
4. Remove the ignition coil.

1. Install the ignition coil to the bracket.
2. Install the ignition coil mounting bolts. Tighten: Tighten the ignition coil mounting bolts to 8 N.m (71 lb in).
3. Connect the ignition coil harness connector.
4. Connect the spark plug wires at the ignition coils.

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

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

1. Remove the spark plug wires. Refer to «Spark Plug Wire Replacement»(ref-187797-S37780683752005090100000) .
2. Loosen each spark plug 1 or 2 turns.
3. Brush or air blast away any dirt from around the spark plugs.
4. Remove the spark plugs 1 at a time. Place each plug in a tray marked with the corresponding cylinder numbers.

1. Properly position each spark plug washer.
2. Inspect each spark plug gap. Adjust each plug as needed. Specification: Spark plug gap: 1.524 mm (0.060 in)
3. Hand start the spark plugs in the corresponding cylinders.
4. Tighten the spark plugs. Tighten: For used heads tighten the spark plugs to 15 N.m (11 lb ft). For new aluminum heads tighten the spark plugs to 20 N.m (15 lb ft). For new iron heads, tighten the spark plugs to 30 N.m (22 lb ft).
5. Install the spark plug wires. Refer to «Spark Plug Wire Replacement»(ref-187797-S37780683752005090100000) .

1. Disconnect the negative battery cable.
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
3. Remove the starter. Refer to «Starter Motor Replacement»(ref-187793-S10226095442005090100000) in Engine Electrical.
4. Disconnect the crankshaft position (CKP) sensor electrical connector.
5. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine.
6. Remove the CKP sensor retaining fastener.
7. Remove the CKP sensor.

1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Cautions and Notices.
2. Install the CKP sensor retaining fastener. Tighten: Tighten the fastener to 25 N.m (18 lb ft).
3. Connect the CKP sensor electrical connector.
4. Install the starter. Refer to «Starter Motor Replacement»(ref-187793-S10226095442005090100000) in Engine Electrical.
5. Lower the vehicle.
6. Connect the negative battery cable.
7. Perform the CKP system variation learn procedure. Refer to «CKP System Variation Learn Procedure»(ref-187797-S26628522322005090100000) .

1. Remove intake manifold. Refer to «Intake Manifold Replacement»(ref-187833-S33717649332005090100000) .
2. Disconnect the electrical connector from the camshaft position (CMP) sensor.
3. Remove the CMP sensor retaining bolt.
4. Remove the CMP sensor.

1. Install the CMP sensor.
2. Install the CMP sensor retaining bolt. Tighten: Tighten the bolt to 29 N.m (21 lb ft).
3. Connect the CMP sensor electrical connector.
4. Install intake manifold. Refer to «Intake Manifold Replacement»(ref-187833-S33717649332005090100000) .

1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-187833-S33717649332005090100000) in Engine Mechanical.
2. Remove the KS wiring harness assembly.
3. Remove the KS.

1. Install the KS. Tighten: Torque the sensor to 20 N.m (15 lb ft).
2. Install the KS wiring harness assembly.
3. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-187833-S33717649332005090100000) in Engine Mechanical.

1. Open the hood.
2. Loosen bolts retaining front air cleaner housing to rear air cleaner housing.
3. Separate front and rear air cleaner housing.
4. Remove air cleaner element.

1. Install air cleaner element.
2. Install rear air cleaner housing to front air cleaner housing.
3. Install front to rear air cleaner housing bolts. Tighten: Tighten bolts to 3 N.m (27 lb in).
4. Close the hood.

1. Open the hood.
2. Remove air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-187797-S41949512502005090100000) .
3. Remove bolts retaining air cleaner housing to upper tie bar.
4. Remove air cleaner housing assembly.

1. Install air cleaner housing assembly.
2. Install bolts to retain air cleaner housing assembly to upper tie bar. Tighten: Tighten bolts to 10 N.m (89 lb in).
3. Install the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-187797-S41949512502005090100000) .
4. Close the hood.

1. Open the hood.
2. Loosen clamp retaining air cleaner outlet duct to rear air box and throttle body.
3. Remove air cleaner outlet duct.

1. Install the air cleaner outlet duct. Tighten: Tighten clamps to 4 N.m (35 lb in).
2. Close the hood.