Engine Controls - Removal & Installation: Other Chevrolet TrailBlazer I

AIR CLEANER OUTLET RESONATOR (4.2L)

Note. Numbers in parentheses refer to numbers in illustrations.

1. Loosen the air cleaner outlet duct and air cleaner outlet resonator clamps (2). (Scheme 112)
2. Disconnect the electrical connector from the intake air temperature (IAT) sensor (1).
3. Disconnect the air cleaner outlet duct from the air cleaner outlet resonator.
4. Disconnect the fuel pressure regulator vacuum supply from the air cleaner outlet resonator.
5. Remove the two air cleaner outlet resonator to engine bolts (4). (Scheme 113)
6. Disconnect the crankcase ventilation hose (1) from the valve cover port (2).
7. Remove the air cleaner outlet resonator assembly (5) from the engine.

Note. Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

1. Install the air cleaner outlet resonator assembly (5) to the engine making sure of the following: The crankcase ventilation hose (1) is connected to the valve cover port (2). (Scheme 113) The air cleaner outlet resonator (5) is properly fit to the throttle body assembly.
2. Install the two air cleaner outlet resonator to engine bolts (4). Tighten the resonator to engine bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159085-S35886898402003111100000).
3. Connect the fuel pressure regulator vacuum supply to the air cleaner outlet resonator.
4. Connect the air cleaner outlet duct to the air cleaner outlet resonator.
5. Connect the electrical connector to the Intake Air Temperature (IAT) sensor (1). (Scheme 112)
6. Properly position the air cleaner outlet duct and air cleaner outlet resonator clamps (2). Tighten the clamps (2) to specification. See «TORQUE SPECIFICATIONS»(ref-159085-S35886898402003111100000).

Scheme 112

Scheme 113

AIR CLEANER RESONATOR OUTLET DUCT

Note. Numbers in parentheses refer to numbers in illustrations.

INTAKE MANIFOLD

Note. Numbers in parentheses refer to numbers in illustrations.

COMPUTERIZED ENGINE CONTROLS

POWERTRAIN CONTROL MODULE

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

THROTTLE ACTUATOR CONTROL MODULE (5.3L)

Note. Numbers in parentheses refer to numbers in illustrations.

1. Remove the bulk connector from the bracket, insert a small flat-bladed tool to disengage the clip.
2. Disconnect the Instrument Panel (I/P) harness electrical connector. (Scheme 114)
3. Disconnect the engine harness electrical connector. (Scheme 115)
4. Release the retaining tab on the side of the Throttle Actuator Control (TAC) module (3). (Scheme 116)
5. Remove the TAC module (3) from the retaining bracket (1).
6. If necessary, remove the TAC module bracket nuts (2) and bracket (1).

1. If necessary, install the TAC module bracket (1) and nuts (2). Tighten the nuts to specification. See «TORQUE SPECIFICATIONS»(ref-159085-S35886898402003111100000). (Scheme 116)
2. Install the TAC module (3) to the retaining bracket (1).
3. Snap the TAC module (3) into retaining tab.
4. Connect the engine harness electrical connector. (Scheme 115)
5. Connect the I/P harness electrical connector. (Scheme 114)
6. Install the bulk connector to the bracket.

Scheme 114

Scheme 115

Scheme 116

4.2L

1. Install scan tool.
2. Using scan tool, monitor the PCM for DTCs. If other DTCs are set, except DTC P1336, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-155898-S19906497452003062800000) in SELF-DIAGNOSTICS - 4.2L BRAVADA, ENVOY, ENVOY XL, TRAILBLAZER & TRAILBLAZER EXT article.
3. With scan tool, select the crankshaft position variation learn procedure.
4. Observe the fuel cut-off for the engine that you are performing the learn procedure on.
5. The scan tool instructs you to perform the following: Block drive wheels. Apply parking brake. Cycle ignition from OFF to ON. Apply and hold brake pedal. Start and idle engine. Turn OFF the A/C. Place transmission in Park (A/T) or Neutral (M/T). The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft Position (CKP) sensor activity. If there is a CKP sensor condition, refer to the applicable DTC that set. See «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-155898-S19906497452003062800000) in SELF-DIAGNOSTICS - 4.2L BRAVADA, ENVOY, ENVOY XL, TRAILBLAZER & TRAILBLAZER EXT article. Camshaft Position (CMP) sensor activity. If there is a CMP sensor condition, refer to the applicable DTC that set. See «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-155898-S19906497452003062800000) in SELF-DIAGNOSTICS - 4.2L BRAVADA, ENVOY, ENVOY XL, TRAILBLAZER & TRAILBLAZER EXT article. Engine Coolant Temperature (ECT). If engine coolant temperature is not warm enough, idle the engine until engine coolant temperature reaches correct temperature.
6. With scan tool, enable the crankshaft position system variation learn procedure.
7. Slowly increase the engine speed to the RPM that you observed.
8. Immediately release the throttle when fuel cut-off is reached.
9. The scan tool displays Learn Status: Learned this ignition. If scan tool does NOT display this message and no additional DTCs set, see «DIAGNOSTIC SYSTEM CHECK - ENGINE CONTROLS»(ref-155898-S30062612662003062800000) under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - 4.2L BRAVADA, ENVOY, ENVOY XL, TRAILBLAZER & TRAILBLAZER EXT article. If a DTC set, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-155898-S19906497452003062800000) in SELF-DIAGNOSTICS - 4.2L BRAVADA, ENVOY, ENVOY XL, TRAILBLAZER & TRAILBLAZER EXT article.
10. Turn ignition off for 30 seconds after the learn procedure is completed successfully.

5.3L

Note. The Crankshaft Position (CKP) system variation learn procedure is required when the following service procedures have been performed, regardless of whether DTC P0315 is set: CKP sensor replacement. Engine replacement. PCM replacement. Harmonic balancer replacement. Crankshaft replacement. Any engine repairs which disturb the CKP sensor relationship. For additional diagnostic information, see DTC P0315: CRANKSHAFT POSITION SENSOR VARIATION NOT LEARNED under DIAGNOSTIC TESTS in SELF-DIAGNOSTICS - 5.3L ENVOY XL & TRAILBLAZER EXT article.

1. Install a scan tool to Data Link Connector (DLC).
2. With a scan tool, monitor the powertrain control module for DTCs. If only DTC P0315 is set, go to next step. If a DTC other than P0315 is set, diagnose that DTC first. See «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-158882-S38387953612003102900000) in SELF-DIAGNOSTICS - 5.3L ENVOY XL & TRAILBLAZER EXT ARTICLE.
3. With a scan tool, select the CRANKSHAFT POSITION VARIATION LEARN PROCEDURE.
4. The scan tool instructs you to perform the following: Set parking brake. Block drive wheels. DO NOT apply brake pedal. Observe fuel cut-off for applicable engine. Accelerate to Wide Open Throttle (WOT). Release throttle when fuel cut-off occurs. Engine should not accelerate beyond calibrated RPM value. Release throttle immediately if value is exceeded. Cycle ignition from OFF to ON. Apply and hold brake pedal. Start and idle engine. Turn A/C OFF. Vehicle must remain in Park or Neutral. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft Position (CKP) sensor activity. If there is a CKP sensor condition, refer to the applicable DTC that set. See «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-158882-S38387953612003102900000) in SELF-DIAGNOSTICS - 5.3L ENVOY XL & TRAILBLAZER EXT article. Camshaft Position (CMP) sensor activity. If there is a CMP sensor condition, refer to the applicable DTC that set. See «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-158882-S38387953612003102900000) in SELF-DIAGNOSTICS - 5.3L ENVOY XL & TRAILBLAZER EXT article. Engine Coolant Temperature (ECT). If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature.
5. With the scan tool, enable the crankshaft position system variation learn procedure.
6. Slowly increase the engine speed to the RPM that you observed.
7. Immediately release the throttle when fuel cut-off is reached.
8. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, see «DIAGNOSTIC SYSTEM CHECK - ENGINE CONTROLS»(ref-158882-S07978614742003102900000) under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - 5.3L ENVOY XL & TRAILBLAZER EXT article. If a DTC set, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-158882-S38387953612003102900000) in SELF-DIAGNOSTICS - 5.3L ENVOY XL & TRAILBLAZER EXT ARTICLE.
9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully.

1. Turn ignition on, with engine off.
2. Fully push and release accelerator pedal slowly 3 times within 5 seconds.
3. If the CHANGE ENG OIL light flashes for 5 seconds, the system is reset. If light does not flash, repeat the procedure.

1. Turn the ignition key to the RUN position.
2. To reset the Oil Life System, use the FUEL button to reach the ENGINE OIL LIFE screen. Press and hold the SELECT button for five seconds while ENGINE OIL LIFE is displayed. OIL LIFE RESET will appear on the display for 10 seconds to let you know the system is reset.

POWERTRAIN CONTROL MODULE (4.2L)

Note. Programing Powertrain Control Module requires a compatible scan tool and a Techline® terminal. Procedure uses a Tech 2™ scanner.

Remote Programming

Note. DO NOT program a control module unless you are directed by a service procedure or you are directed by a technical service bulletin. Programming a control module at any other time will not permanently correct a customer's concern.

Remote Programming

1. Connect Tech 2™ scan tool to vehicle and obtain the module information using the following procedures: NOTE: Ensure control module is installed in vehicle and battery is fully charged before programming. Ensure engine and Tech 2™ is off. Connect Tech 2™ to Data Link Connector (DLC). Turn ON the Tech 2™. Press ENTER at the title screen. Turn ignition on, with engine off. Select Service Programming System at the Main Menu. NOTE: Select Request Info Again if a Vehicle Identification Number (VIN) was previously stored in scan tool. Select Request Info. Enter vehicle description by following the on-screen instructions. Turn OFF all accessories and select CONTINUE. NOTE: Select No and write down the VIN if the VIN is incorrect. Verify that the correct VIN is entered on the Tech 2™ and select YES.
2. Turn off the Tech 2™ scan tool.
3. Disconnect Tech 2™ from vehicle.
4. Turn ignition off.
5. Transfer the data from the terminal to the Tech 2™ using the following procedure: Connect the Tech 2™ to the terminal. NOTE: The TIS supports service programming with the Tech 2™ scan tool only. Launch the TIS application at the terminal. Select the Service Programming System at the main screen. Highlight the following information on the Select Diagnostic Tool and Programming Process Screen: Select Diagnostic Tool. Select Tech 2™. Select Programming Process. Identify whether an existing module is being reprogrammed or a module is being replaced with a new one. Select ECU Location. Select vehicle. Select NEXT. Verify the connections and select NEXT. NOTE: You may receive a message stating that the control module could be a service control module if you selected NO to the VIN being correct. Click OK. Verify the VIN and select NEXT. Select the appropriate controller for the vehicle being serviced. NOTE: When selecting the Vehicle Configuration Index (VCI) programming type, a valid VCI number for the vehicle must be entered. This number may be obtained from the Techline Customer Support. Select the type of programming to be performed from the following categories: Normal. Used for updating an existing calibration or programming a new controller. Vehicle Configuration Index (VCI). Used for updating an existing controller or programming a new controller for newer vehicles whose VINs are not yet in the database. Reconfigure. Used to reconfigure a vehicle for changes in tire size and axle ratios. Select Next. NOTE: Refer to service bulletins before service programming is performed if the bulletins are listed along with the calibration files. Select the appropriate calibration file for the vehicle being serviced. Select NEXT. NOTE: Select Cancel if you receive a message stating that the calibration selected is already the current calibration in the control module and reprogramming with the same download is not allowed. Verify your selection on the Summary screen. Select NEXT.
6. Perform the Crankshaft Position Variation Relearn Procedure using the Special Functions feature, if applicable.
7. Close the application and return to the TIS application Selection screen after the download is complete.
8. Turn OFF the Tech 2™.
9. Disconnect Tech 2™ from the terminal.
10. Transfer the data from the Tech 2™ to the control module using the following procedure: Connect the Tech 2™ to DLC, with engine and Tech 2™ OFF. Turn ON the Tech 2™. Press ENTER at the title screen. Turn ignition on, with engine off. Select Service Programming System. Select the Program ECU function on the Tech 2™. Verify the VIN and calibration numbers, select CONTINUE. Follow the on-screen instructions and select CONTINUE. Select continue and exit the program after the Tech 2™ displays Programming Was Successful.
11. Turn ignition off.
12. Turn OFF the Tech 2™.
13. Disconnect the Tech 2™ from the vehicle.

Programming Verification

1. Turn ignition off for 30 seconds.
2. Start engine.

Pass-Thru Procedure

Pass-Thru programming allows scan tool to remain connected to the terminal and to the vehicle throughout the programming process. The vehicle must be in close proximity to the terminal while using Pass-Thru procedure.

Note. The TIS supports service programming with the Tech 2™ scan tool only.

1. Launch the TIS application at the terminal.
2. Select the Service Programming System.
3. Highlight the following information on the Select Diagnostic Tool Programming Process screen: Select Diagnostic Tool. Select Pass-Thru. Select Programming Process. Identify whether an existing module is being reprogrammed or a module is being replaced with a new one. Select ECU Location. Select vehicle.
4. Select Next.
5. Complete all terminal-directed data on the Preparing for Communication/Determine Vehicle screen until Next is highlighted.
6. Select Next.
7. Follow the instructions on the Preparing for Communication screen.
8. Select Next.
9. Verify the VIN on the Validate Vehicle Identification Number screen.
10. Select Next.
11. If an option screen appears, verify the vehicle configuration and/or RPO information.
12. Select Next.
13. Highlight the appropriate control module and programming type on the Supported Controllers screen.
14. Select Next.
15. Select the proper calibrations on the Calibration Selection screen.
16. Ensure all the folder tabs have a green check mark.
17. Select Next.
18. Verify the current calibrations with the selected calibrations.
19. Select Next.
20. The Transfer Data screen will appear until the progress bar reaches 100 percent. This may take up to 30 minutes.
21. Complete all of the terminal-directed data on the Programming Complete screen.
22. Turn OFF the Tech 2™.
23. Disconnect the Tech 2™ from the vehicle.

Off-Board Remote Procedure

The Off-Board Programming Adapter Kit (J-41207-C) is required when a module must be programmed without having the vehicle present. The adapter allows the module to be turned ON and communicate with scan tool.

Note. Ensure Tech 2™ scan tool and terminal are both equipped with the latest software before performing programming.

1. Obtain the Vehicle Identification Number (VIN) of the vehicle for which the module is being programmed.
2. Launch the TIS application at the terminal.
3. Select the Service Programming System.
4. Highlight the following information on the Select Diagnostic Tool and Programming Process screen: Select Diagnostic Tool-Select Tech 2™ scan tool. Select Programming Process. Identify whether an existing module is being reprogrammed or replaced with a new one. Select ECU location. Select Off-Board Programming Adapter.
5. Select Next.
6. Follow the directions on the Preparing for Communication screen for connecting the following components: The control module. The Off-Board Programming Adapter (OBPA). Refer to TIS Users Guide for a listing of the OBPA. Tech 2™ scan tool.
7. Select the Service Programming Request Information function on the Tech 2™.
8. Follow the Tech 2 instructions to obtain the module data and security information.
9. After the Tech 2™ has received the data from the module, exit the Request Info mode.
10. Disconnect the Tech 2™ from the OBPA.
11. Turn OFF the Tech 2™.
12. Connect the Tech 2™ to the terminal.
13. Turn ON the Tech 2™.
14. Select Next at the terminal after the Tech 2™ start-up screen appears.
15. Enter the VIN of the vehicle that will be receiving the control module.
16. Select Next.
17. Select the type of programming to be performed from the following categories: Normal. Used for updating an existing calibration or programming a new controller. Vehicle Configuration Index (VCI). Used for updating an existing controller or programming a new controller for newer vehicles whose VINs are not yet in the database. Reconfigure. Used to reconfigure a vehicle for changes in tire size and axle ratios.
18. Select Next.
19. Select a calibration on the Calibration Selection screen, if necessary.
20. Ensure all the desired folder tabs have a Green check mark.
21. Select Next.
22. Verify the current and the selected calibration of the control module on the Summary screen.
23. Select Next.
24. Select OK.
25. On model year 1996 and newer controllers, a Crankshaft Position (CKP) relearn procedure box may appear. Select OK.
26. Follow the on-screen instructions, if any, when the Program Controller/Programming Complete screen appears.
27. Select Close.
28. Turn OFF the Tech 2™.
29. Disconnect the Tech 2™ from the terminal.
30. Connect the Tech 2™ to the OBPA.
31. Turn ON the Tech 2™.
32. Select Enter at the title screen.
33. Select the Service Programming System at the Main Menu.
34. Select the Program ECU function.
35. Select Continue.
36. Follow the on-screen instructions.
37. Select Continue.
38. Select Exit when the programming is complete.
39. Turn OFF the OBPA.
40. Turn OFF the Tech 2™.
41. Disconnect the OBPA from the Tech 2™ and the control module.

Off-Board Pass-Thru Procedure

The Off-Board Programming Adapter Kit (J-41207-C) is required when a module must be programmed without having the vehicle present. The adapter allows the module to be turned ON and communicate with scan tool.

Note. Ensure Tech 2™ scan tool and terminal are both equipped with the latest software before performing programming.

1. Launch the TIS application in the terminal.
2. Select the Service Programming System.
3. Highlight the following information on the Select Diagnostic Tool and Programming Process Screen: Select Diagnostic Tool. Select Pass-Thru. Select Programming Process. Identify whether an existing module is being reprogrammed, or a module is being replaced with a new one. Select ECU location. Select Off-Board Programming Adapter.
4. Select Next.
5. Complete all terminal-directed data at the Preparing for Communication/Determine Vehicle screen until Next is highlighted.
6. Select Next.
7. Follow the on-screen instructions for connecting the following components: The control module. The Off-Board Programming Adapter (OBPA). Refer to TIS user's guide for a listing of OBPA. Tech 2™.
8. Select Next.
9. Pass-Thru displays the VIN stored in the control module. If a new control module is being programmed, enter the correct VIN of the vehicle.
10. Select Next.
11. Select the appropriate options if the Options screen appears.
12. Select Next.
13. Select the type of programming to be performed from the following categories: Normal. Used for updating an existing calibration or programming a new controller. Vehicle Configuration Index (VCI). Used for updating an existing controller or programming a new controller for newer vehicles whose VINs are not yet in the database. Reconfigure. Used to reconfigure a vehicle for changes in tire size and axle ratios.
14. Select Next.
15. Select a calibration selection on the Calibration Selection screen, if necessary.
16. Ensure all the desired calibration folder tabs have a Green check mark.
17. Select Next.
18. Verify the current and selected calibration of the control module on the Summary screen.
19. Select Next.
20. Select OK.
21. Select OK.
22. When programming is complete, a Program Controller/Programming Complete screen appears. Follow the on-screen instructions, if any.
23. Select Close.
24. Turn OFF the OBPA.
25. Turn OFF scan tool.
26. Disconnect the OBPA from the Tech 2™ and the control module.

POWERTRAIN CONTROL MODULE (5.3L)

Note. Service of the PCM should normally consist of either replacement of the PCM or EEPROM programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be checked first to see if it is the correct part. If it is, remove the faulty PCM and install the new service PCM. The service PCM EEPROM will not be programmed. DTC P0601 and P0602 indicates the EEPROM is not programmed or has malfunctioned.

Note. Programing Powertrain Control Module requires a compatible scan tool and a Techline® terminal. Procedure uses a Tech 2® scan tool.

Note. DO NOT program a control module unless you are directed by a service procedure or you are directed by a technical service bulletin. Programming a control module at any other time will not permanently correct a customer's concern.

1. Turn OFF the ignition.
2. Install the Tech 2® to the data link connector (DLC), with the Tech 2® turned OFF.
3. Turn ON Tech 2®. Press ENTER at title screen.
4. Turn ON the ignition, with the engine OFF.
5. Turn OFF all vehicle accessories.
6. Select SERVICE PROGRAMMING SYSTEM at the MAIN MENU.
7. Select REQUEST INFO.
8. Enter the vehicle description by following the on-screen instructions.
9. Verify that the correct VIN is entered on the Tech 2® and select YES.
10. Turn OFF the Tech 2®.
11. Disconnect the Tech 2® from the vehicle.
12. Turn OFF the ignition.
13. Connect the Tech 2® to the terminal.
14. Launch the TIS application at the terminal.
15. Select the SERVICE PROGRAMMING SYSTEM at the main screen.
16. Highlight the following information on the Select Diagnostic Tool and Programming Process Screen: Select DIAGNOSTIC TOOL, then select Tech 2®. Select PROGRAMMING PROCESS. Identify whether an existing module is being reprogrammed or a module is being replaced with a new one. Select ECU LOCATION. Select vehicle.
17. Select NEXT.
18. Verify the connections and select NEXT.
19. Verify the VIN and select NEXT.
20. Select the appropriate controller for the vehicle being serviced.
21. Select the type of programming to be performed from the following categories: NORMAL - Used for updating an existing calibration or programming a new controller. VEHICLE CONFIGURATION INDEX (VCI) - Used for updating an existing controller or programming a new controller for newer vehicles whose VINs are not yet in the database. RECONFIGURE - Used to reconfigure a vehicle for changes in tire size and/or axle ratios.
22. Select NEXT.
23. Select the appropriate calibration file for the vehicle being serviced.
24. Select NEXT.
25. Verify your selection on the Summary screen.
26. Select NEXT.
27. Perform the CRANKSHAFT POSITION VARIATION RELEARN PROCEDURE using the SPECIAL FUNCTIONS feature, if applicable.
28. Close the application and return to the TIS APPLICATION SELECTION screen after the download is complete.
29. Turn OFF the Tech 2®.
30. Disconnect the Tech 2® from the terminal.
31. Connect the Tech 2® to the vehicle DLC, with the engine and the Tech 2® OFF.
32. Turn ON the Tech 2®.
33. Press ENTER at the TITLE screen.
34. Turn ON the ignition, with the engine OFF.
35. Select SERVICE PROGRAMMING SYSTEM.
36. Select the PROGRAM ECU function on the Tech 2®.
37. Verify the VIN and calibration numbers, select CONTINUE.
38. Follow the on-screen instructions and select CONTINUE.
39. Select CONTINUE and exit the program after the Tech 2® displays PROGRAMMING WAS SUCCESSFUL.
40. Turn OFF the ignition.
41. Turn OFF the Tech 2®.
42. Disconnect the Tech 2® from the vehicle.
43. Verify the control module programming was successful. Turn OFF the ignition for 30 seconds.
44. Start the engine. Repeat the Service Programming System procedure if the vehicle does not start or starts but runs rough.

Off-Board Remote Programming

Note. The Off-Board Programming Adapter Kit (J 41207-C) is required when a module must be programmed without having the vehicle present. The adapter allows the module to be turned ON and communicate with the scan tool.

1. Obtain the Vehicle Identification Number (VIN) of the vehicle for which the module is being programmed.
2. Launch the TIS application at the terminal.
3. Select the SERVICE PROGRAMMING SYSTEM.
4. Highlight the following information on the Select Diagnostic Tool and Programming Process Screen: Select DIAGNOSTIC TOOL, then select Tech 2®. Select PROGRAMMING PROCESS. Identify whether an existing module is being reprogrammed or a module is being replaced with a new one. Select ECU LOCATION. Select OFF-BOARD PROGRAMMING ADAPTER.
5. Select NEXT.
6. Follow the directions on the Preparing for Communication screen for connecting the following components: The control module. The Off-Board Programming Adapter (OBPA). Refer to the TIS users guide for a listing of the OBPA. The Tech 2®.
7. Select the SERVICE PROGRAMMING REQUEST INFORMATION function on the Tech 2®.
8. Follow the Tech 2® instructions to obtain the module data and security information.
9. After the Tech 2® has received the data from the module, exit the Request Info mode.
10. Disconnect the Tech 2® from the OBPA.
11. Turn OFF the Tech 2®.
12. Connect the Tech 2® to the terminal.
13. Turn ON the Tech 2®.
14. Select NEXT at the terminal after the Tech 2® start-up screen appears.
15. Enter the VIN of the vehicle that will be receiving the control module.
16. Select NEXT.
17. Select the type of programming to be performed from the following categories: NORMAL - Used for updating an existing calibration or programming a new controller. VEHICLE CONFIGURATION INDEX (VCI) - Used for updating an existing controller or programming a new controller for newer vehicles whose VINs are not yet in the database. RECONFIGURE - Used to reconfigure a vehicle for changes in tire size and/or axle ratios.
18. Select NEXT.
19. Select a calibration on the Calibration Selection screen, if necessary.
20. Ensure all the desired folder tabs have a green check mark.
21. Select NEXT.
22. Verify the current and the selected calibration of the control module on the Summary screen.
23. Select NEXT.
24. Select OK.
25. On model year 1996 and newer controllers, a Crankshaft Position (CKP) relearn procedure box may appear. Select OK.
26. Follow the on-screen instructions, if any, when the Program Controller/Programming Complete screen appears.
27. Select CLOSE.
28. Turn OFF the Tech 2®.
29. Disconnect the Tech 2® from the terminal.
30. Connect the Tech 2® to the OBPA.
31. Turn ON the Tech 2®.
32. Select Enter at the title screen.
33. Select the SERVICE PROGRAMMING SYSTEM at the Main Menu.
34. Select the PROGRAM ECU function.
35. Select CONTINUE.
36. Follow the on-screen instructions.
37. Select Continue.
38. Select EXIT when the programming is complete.
39. Turn OFF the OBPA.
40. Turn OFF the Tech 2®.
41. Disconnect the OBPA from the Tech 2® and the control module.

Off-Board Pass-Thru Programming

Note. The Off-Board Programming Adapter Kit (J 41207-C) is required when a module must be programmed without having the vehicle present. The adapter allows the module to be turned ON and communicate with the scan tool.

1. Launch the TIS application at the terminal.
2. Select the SERVICE PROGRAMMING SYSTEM.
3. Highlight the following information on the Select Diagnostic Tool and Programming Process Screen: Select DIAGNOSTIC TOOL, then select PASS-THRU. Select PROGRAMMING PROCESS. Identify whether an existing module is being reprogrammed or a module is being replaced with a new one. Select ECU LOCATION. Select OFF-BOARD PROGRAMMING ADAPTER.
4. Select NEXT.
5. Complete all terminal-directed data at the Preparing for Communication/Determine Vehicle screen until NEXT is highlighted.
6. Select NEXT.
7. Follow the on-screen instructions for connecting the following components: The control module. The Off-Board Programming Adapter (OBPA). Refer to the TIS users guide for a listing of the OBPA. The Tech 2®.
8. Select NEXT.
9. Pass-Thru displays the VIN stored in the control module. If a new control module is being programmed, enter the correct VIN of the vehicle.
10. Select NEXT.
11. Select the appropriate options if the Options screen appears.
12. Select NEXT.
13. Select the type of programming to be performed from the following categories: NORMAL - Used for updating an existing calibration or programming a new controller. VEHICLE CONFIGURATION INDEX (VCI) - Used for updating an existing controller or programming a new controller for newer vehicles whose VINs are not yet in the database. RECONFIGURE - Used to reconfigure a vehicle for changes in tire size and/or axle ratios.
14. Select NEXT.
15. Select a calibration on the Calibration Selection screen, if necessary.
16. Ensure all the desired folder tabs have a green check mark.
17. Select NEXT.
18. Verify the current and the selected calibration of the control module on the Summary screen.
19. Select NEXT.
20. Select OK.
21. On model year 1996 and newer controllers, a Crankshaft Position (CKP) relearn procedure box may appear. Select OK.
22. Follow the on-screen instructions, if any, when the Program Controller/Programming Complete screen appears.
23. Select CLOSE.
24. Turn OFF the OBPA.
25. Turn OFF the Tech 2®.
26. Disconnect the OBPA from the Tech 2® and the control module.

Pass-Thru Programming

Note. Pass-Thru programming allows the scan tool to remain connected to the terminal and to the vehicle throughout the programming process. The vehicle must be in close proximity to the terminal while using Pass-Thru.

1. Launch the TIS application at the terminal.
2. Select the SERVICE PROGRAMMING SYSTEM.
3. Highlight the following information on the Select Diagnostic Tool and Programming Process Screen: Select DIAGNOSTIC TOOL, then select PASS-THRU. Select PROGRAMMING PROCESS. Identify whether an existing module is being reprogrammed or a module is being replaced with a new one. Select ECU LOCATION. Select VEHICLE.
4. Select NEXT.
5. Complete all terminal-directed data on the Preparing for Communication/Determine Vehicle screen until NEXT is highlighted.
6. Select NEXT.
7. Follow the instructions on the Preparing for Communication screen.
8. Select NEXT.
9. Verify the VIN on the VALIDATE VEHICLE IDENTIFICATION NUMBER screen.
10. Select NEXT.
11. If an option screen appears, verify the vehicle configuration and/or RPO information.
12. Select NEXT.
13. Highlight the appropriate control module and programming type on the SUPPORTED CONTROLLERS screen.
14. Select NEXT.
15. Select the proper calibrations on the CALIBRATION SELECTION screen.
16. Ensure all the folder tabs have a green check mark.
17. Select NEXT.
18. Verify the current calibrations with the selected calibrations.
19. Select NEXT.
20. The TRANSFER DATA screen will appear until the progress bar reaches 100 percent. This may take up to 30 minutes.
21. Complete all of the terminal-directed data on the PROGRAMMING COMPLETE screen.
22. Turn OFF the Tech 2®.
23. Disconnect the Tech 2® from the vehicle.

THEFT DETERRENT LEARN PROCEDURE

There are 2 available methods to perform the programming procedure

1. The 10-minute procedure which requires a Tech 2™ and a Techline® terminal.
2. The 30-minute procedure which does not require the use of any tools.

10-Minute Learn Procedure

Note. Tools required are Tech 2™ scan tool and Techline® terminal with current Service Programming System (SPS) software.

1. Connect the Tech 2™ to vehicle.
2. Select "Request Information" under "Service Programming".
3. Disconnect the Tech 2™ from vehicle and connect it to a Techline® terminal.
4. On the Techline™ terminal, select "Theft Module Re-Learn" under "Service Programming".
5. Disconnect the Tech 2™ from the Techline™ terminal and connect it to the vehicle.
6. Turn ignition on, with engine off.
7. Select "VTD Re-Learn" under "Service Programming".
8. Attempt to start engine, then release the key to ON (vehicle will not start).
9. Observe the SECURITY telltale, after approximately 10 minutes the telltale will turn OFF (the vehicle is now ready to relearn the Passlock™ Sensor Data Code and/or password on the next ignition switch transition from OFF to CRANK).
10. Turn ignition off, and wait 5 seconds.
11. Start engine (vehicle has now learned the password).
12. With Tech 2™ scan tool, clear any DTCs.

30-Minute Learn Procedure

1. Turn ignition on, with engine off.
2. Attempt to start engine, then release the key to ON (vehicle will not start).
3. Observe the SECURITY telltale, after approximately 10 minutes the telltale will turn OFF.
4. Turn ignition off and wait 5 seconds.
5. Repeat steps 1 - 4 two more times for a total of 3 cycles/30 minutes (the vehicle is now ready to relearn the Passlock™ Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK).
6. Start engine (vehicle has now learned the Passlock™ Sensor Data Code and/or password).
7. With scan tool, clear any DTCs if needed (history DTCs will self clear after 100 ignition cycles).

MANIFOLD ABSOLUTE PRESSURE SENSOR

Note. Numbers in parentheses refer to numbers in illustrations.

OXYGEN SENSORS (4.2L)

Note. The Heated Oxygen Sensor 1 (HO2S 1) is located in the exhaust manifold. see scheme 67 Heated Oxygen Sensor 2 (HO2S 2) is mounted in the exhaust pipe behind the catalytic converter. see scheme 68 Oxygen sensors are equipped with a permanent pigtail which must remain intact when removing sensor.

OXYGEN SENSORS (5.3L)

Note. The oxygen sensor may be difficult to remove when the engine temperature is below 120°F (48°C). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.

EVAP CANISTER PURGE SOLENOID

Note. Numbers in parentheses refer to numbers in illustrations.

FUEL SYSTEMS

Remove fuel tank cap. Remove fuel pump relay from underhood junction block. (Scheme 117) Crank engine. Allow engine to start and stall. Crank the engine an additional 3 seconds. Turn ignition off. Disconnect negative battery cable. Install and tighten fuel filler cap. Install fuel pump relay.

Scheme 117

1. Disconnect the negative battery cable.
2. Install the Fitting Tool Set (J 34730-1A).
3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure.
4. Open the valve on Fitting Tool Set in order to bleed the system pressure. The fuel connections are now safe for servicing.
5. Drain any fuel remaining in the gauge into an approved container.
6. Once the system pressure is completely relieved, remove the Fitting Tool Set.

FUEL LINE DISCONNECT FITTINGS (4.2L)

Note. Fuel line disconnect fittings may contain metal or plastic collar. see scheme 80and see scheme 81. Determine type of disconnect fitting used and use proper procedure for type of disconnect fitting being serviced.

FUEL LINE DISCONNECT FITTINGS (5.3L)

Note. Fuel line disconnect fittings may contain metal or plastic collar. see scheme 82and see scheme 83. Determine type of disconnect fitting used and use proper procedure for type of disconnect fitting being serviced.

FUEL RAIL CROSSOVER PIPE (5.3L)

Note. Numbers in parentheses refer to numbers in illustrations.

1. Relieve the fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-159085-S07303999702003111100000).
2. Disconnect the fuel feed and return pipes (1) from the fuel rail. see scheme 104 See «FUEL LINE DISCONNECT FITTINGS (5.3L)»(ref-159085-S42498279002003111900000).
3. Remove the fuel return pipe attaching screw (3) and the fuel return pipe retainer (2). see scheme 97
4. Remove the fuel return pipe (1).
5. Remove and discard the fuel return pipe "O" ring (6).
6. Remove the fuel pressure connection core assembly (24) from the crossover pipe (25).
7. Remove the retaining clip attaching screw (22) and the crossover fuel pipe retainer clip (21).
8. Remove the retaining clip attaching screw (4) and the crossover fuel pipe retainer clip (5).
9. Remove the crossover pipe rail assembly (25) from the left hand fuel rail assembly (14) and the right hand rail assembly (15).
10. Remove and discard the crossover fuel pipe "O" rings (7, 20).

1. Lubricate the NEW crossover fuel pipe "O" rings (7, 20) with clean engine oil. see scheme 97
2. Install the NEW crossover fuel pipe "O" rings (7, 20) onto the crossover pipe rail assembly (25).
3. Install the crossover pipe rail assembly (25) to the left hand rail assembly (14) and the right hand rail assembly (15). CAUTION: When installing the retaining clip attaching screws for the crossover pipe, always start them by hand. This will prevent consequent stripping of the threads on the rail.
4. Install the crossover fuel pipe 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 NEW fuel return pipe "O" ring (6) on the fuel return pipe (1).
7. Install the fuel return pipe (1).
8. Install the fuel return pipe retainer (2). Loosely install the fuel return pipe attaching screw (3).
9. Install the crossover fuel pipe retainer clip (5). Loosely install the retainer clip attaching screw (4). Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-159085-S35886898402003111100000).
10. Tighten the crossover fuel pipe retainer clip attaching screws (4, 22) to specification. See «TORQUE SPECIFICATIONS»(ref-159085-S35886898402003111100000).
11. Tighten the fuel return pipe attaching screw (3) to specification. See «TORQUE SPECIFICATIONS»(ref-159085-S35886898402003111100000).
12. Install the fuel pressure connection core assembly (24) to the crossover pipe rail assembly (25).
13. Connect the fuel feed and return pipes (1) to the fuel rail. see scheme 104 See «FUEL LINE DISCONNECT FITTINGS (5.3L)»(ref-159085-S42498279002003111900000).
14. Install the fuel fill cap.
15. Connect the negative battery cable.
16. 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.

FUEL RAIL OUTLET PIPE (5.3L)

Note. Numbers in parentheses refer to numbers in illustrations.

1. Relieve the fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-159085-S07303999702003111100000).
2. Disconnect the fuel return pipe (1) from the fuel rail. See «FUEL LINE DISCONNECT FITTINGS (5.3L)»(ref-159085-S42498279002003111900000). see scheme 104
3. Remove the retaining clip attaching screw (4). see scheme 97
4. Remove the crossover fuel pipe retainer clip (5).
5. Remove the fuel return pipe attaching screw (3) and the fuel return pipe retainer (2).
6. Remove the fuel return pipe (1).
7. Remove and discard the fuel return pipe "O" ring (6).

1. Lubricate a NEW fuel return pipe "O" ring (6) with clean engine oil. see scheme 97
2. Install the fuel return pipe "O" ring (6) onto the fuel return pipe (1).
3. Install the fuel return pipe (1).
4. Install the fuel return pipe retainer (2) and the fuel return pipe attaching screw (3).
5. Install the retaining clip attaching screw (4).
6. Tighten the crossover fuel pipe retainer clip attaching screws (4) to specification. See «TORQUE SPECIFICATIONS»(ref-159085-S35886898402003111100000).
7. Tighten the fuel return pipe attaching screw (3) to specification. See «TORQUE SPECIFICATIONS»(ref-159085-S35886898402003111100000).
8. Connect the fuel return pipe (1) to the fuel rail. See «FUEL LINE DISCONNECT FITTINGS (5.3L)»(ref-159085-S42498279002003111900000). see scheme 104
9. Install the fuel fill cap.
10. Connect the negative battery cable.
11. 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.

EVAP CANISTER

Note. Numbers in parentheses refer to numbers in illustrations.

Cleaning Procedure

1. Remove EVAP canister. See «EVAP CANISTER»(ref-159085-S24518011622003111100000) . Turn main valve to OFF position on EVAP Pressure/Purge Diagnostic Station. Disconnect hose from EVAP Pressure/Purge Diagnostic Station pressure regulator. Using a section of vacuum hose, connect one end to EVAP Pressure/Purge Diagnostic Station pressure regulator. Connect other end of vacuum hose to EVAP canister side of purge pipe.
2. Turn main nitrogen cylinder valve to ON and continue to discharge nitrogen for 15 seconds. If the nitrogen does not dislodge the carbon particles, replace the purge pipe. Replace EVAP canister. Continue with DTC test.