Engine Control System - 4.2L - Introduction: Removal & Installation GMC Envoy II

Powertrain Control Module (PCM) Replacement

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

Removal Procedure

1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life.
2. Loosen the PCM harness connector bolts (4) from the center of the PCM harness connectors.
3. Remove the PCM harness connectors (2) from the PCM (1).
4. Remove the PCM retaining bolts (3) and nuts (6).
5. Slide the PCM (1) away from the intake manifold past the mounting studs (5) and remove PCM from the vehicle.
6. Remove the PCM mounting studs (5) from the intake manifold only if replacing the studs.

Installation Procedure

1. Install the PCM mounting studs (5) to the intake manifold, if removed. Tighten: Tighten the studs to 6 N.m (53 lb in).
2. Install the PCM (1) onto the studs (5).
3. Install the PCM retaining bolts (3). Tighten: Tighten the bolts to 8 N.m (71 lb in).
4. Install the PCM retaining nuts (6). Tighten: Tighten the nuts to 8 N.m (71 lb in).
5. Install the PCM harness connectors (2) to the PCM body.
6. Tighten the PCM harness connector retaining bolts (4). Tighten: Tighten the bolts to 8 N.m (71 lb in).
7. If a new PCM is being installed, the PCM must be programmed. Refer to «Control Module References»(ref-200358-S22779820132005102000000) in Computer/Integrating Systems.

1. Turn the engine OFF.
2. Disconnect the negative battery terminal.
3. Drain coolant below the level of the ECT sensor. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) in Engine Cooling.
4. Disconnect the ECT sensor electrical connector (1).
5. Remove the drive belt and the generator. Refer to «Generator Replacement (4.2L Engine)»(ref-200375-S31589748562005102000000) or «Generator Replacement (5.3L Engine)»(ref-200375-S15757633622005102000000) in Engine Electrical.
6. Carefully remove the ECT sensor (1).

1. If installing the original sensor or a new sensor without sealant, apply thread sealer P/N 12346004 or equivalent.
2. Install the ECT sensor. Tighten: Tighten the ECT sensor to 16 N.m (12 lb ft).
3. Connect the ECT electrical connector (1).
4. Install the generator and the drive belt. Refer to «Generator Replacement (4.2L Engine)»(ref-200375-S31589748562005102000000) or «Generator Replacement (5.3L Engine)»(ref-200375-S15757633622005102000000) in Engine Electrical.
5. Connect the negative battery terminal.
6. Refill the engine coolant. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) in Engine Cooling.

1. Disconnect the intake air temperature (IAT) sensor electrical connector.
2. Remove the IAT sensor (1) from the air duct with a twisting and pulling motion.

1. Install the IAT sensor (1) to the air duct with a pushing and twisting motion.
2. Reconnect the IAT sensor electrical connector.

1. Turn OFF the ignition.
2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
3. Press the retainer locking tabs inward, then pull the retainer (1) up to remove it.
4. Remove the MAP sensor (2).
5. Inspect the MAP sensor seal for damage, and replace as necessary.

1. Install the MAP sensor (2).
2. Install the MAP sensor retainer (1).
3. Connect the electrical connector.

Note. Refer to Heated Oxygen Sensor (HO2S) Resistance Learn Reset Notice in Cautions and Notices.

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

1. Disconnect the heated oxygen sensor (HO2S) electrical connector (1).
2. Remove the HO2S (2) using a J 39194-B . See «Special Tools & Equipment»(ref-200372-S36410128202005102000000) .

1. Coat the threads of the heated oxygen sensor with the anti-seize compound P/N 5613695, or the equivalent if necessary.
2. Install the heated oxygen sensor (2) using a J 39194-B . See «Special Tools & Equipment»(ref-200372-S36410128202005102000000) . Tighten: Tighten the HO2S to 41 N.m (30 lb ft).
3. Connect the HO2S electrical connector (1).

Note. Refer to Heated Oxygen Sensor (HO2S) Resistance Learn Reset Notice in Cautions and Notices.

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

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
2. Disconnect the heated oxygen sensor (HO2S) electrical connector (1).
3. Remove the HO2S (2) using a J 39194-B . See «Special Tools & Equipment»(ref-200372-S36410128202005102000000) .

1. Coat the threads of the heated oxygen sensor with the anti-seize compound P/N 5613695, or the equivalent if necessary.
2. Install the heated oxygen sensor (2) using a J 39194-B . See «Special Tools & Equipment»(ref-200372-S36410128202005102000000) . Tighten: Tighten the HO2S to 41 N.m (30 lb ft).
3. Connect the HO2S electrical connector (1).
4. Lower the vehicle.

1. Disconnect the accelerator pedal position (APP) sensor electrical connector.
2. Remove the APP sensor retaining fasteners.
3. Remove the APP sensor (2) from the vehicle.

1. Install the APP sensor (2) to vehicle.
2. Install the APP sensor retaining fasteners (1). Tighten: Tighten the retaining fasteners to 10 N.m (89 lb in).
3. Connect the APP sensor electrical connector.

1. Remove the resonator assembly. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-200372-S19209944462005102000000) .
2. Remove the evaporative emission (EVAP) canister purge line from the throttle body.
3. Disconnect the throttle body electrical connector.
4. Remove the throttle body assembly retaining bolts (1).
5. Remove the throttle body assembly (2) and the gasket from the intake manifold.
6. Clean the gasket surface.

1. Install the throttle body assembly (2) to the intake manifold with the gasket.
2. Add sealer GM P/N 12346004 (Canadian P/N 10953480) to the throttle control module bolt threads.
3. Install the throttle body assembly retaining bolts (1). Tighten: Tighten the bolts to 10 N.m (89 lb in).
4. Connect the throttle body electrical connector.
5. Install the EVAP canister purge line to the throttle body.
6. Install the resonator assembly. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-200372-S19209944462005102000000) .

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
2. Only if necessary remove the fuel tank shield. Refer to «Fuel Tank Shield Replacement (TrailBlazer, Envoy)»(ref-200388-S37284800062005102000000) or «Fuel Tank Shield Replacement (TrailBlazer EXT, Envoy XL)»(ref-200388-S31467977892005102000000) in Frame and Underbody.
3. Remove the fuel pressure service connection cap, located near the fuel filter.
4. Install the J 34730-1A fuel pressure gage to the fuel pressure service connection, located near the fuel filter. See «Special Tools & Equipment»(ref-200372-S36410128202005102000000) .
5. Turn ON the ignition.
6. Place the bleed hose of the fuel pressure gage into an approved gasoline container.
7. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage.
8. Command the fuel pump ON with a scan tool.
9. Close the bleed valve on the fuel pressure gage.
10. Inspect for fuel leaks.

1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure.
2. Place a shop towel under the fuel pressure gage adaptor fitting to catch any remaining fuel spillage.
3. Remove the J 34730-1A from the pressure gage fitting. See «Special Tools & Equipment»(ref-200372-S36410128202005102000000) .
4. Drain any fuel remaining in the fuel pressure gage into an approved container.
5. Install the fuel pressure service connection cap.
6. 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.
7. Install the fuel tank shield if removed. Refer to «Fuel Tank Shield Replacement (TrailBlazer, Envoy)»(ref-200388-S37284800062005102000000) or «Fuel Tank Shield Replacement (TrailBlazer EXT, Envoy XL)»(ref-200388-S31467977892005102000000) in Frame and Underbody.

1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the «Fuel Pressure Relief Procedure»(ref-200372-S19996306352005102000000) .
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 for the size of the fitting. See «Special Tools & Equipment»(ref-200372-S36410128202005102000000) . 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.

Scheme 20

1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the «Fuel Pressure Relief Procedure»(ref-200372-S19996306352005102000000) .
2. Using compressed air, blow any dirt out of the quick-connect fitting.
3. This step applies to Bartholomew style connectors ONLY. Squeeze the plastic quick connect fitting release tabs.
4. This step applies to Q Release style connectors ONLY. Release the fitting by Pushing the tab toward the other side of the slot in the fitting.
5. This step applies to Squeeze to Release style connectors ONLY. Squeeze where indicated by arrows on both sides of the plastic ring surrounding the quick connect fitting.
6. This step applies to Sliding Retainer style connectors ONLY. Release the fitting by pressing on one side of the release tab causing it to push in slightly. If the tab does not move, try pressing the tab in from the opposite side. The tab will only move in one direction.
7. This step applies to the Push Down TI style connectors ONLY. Release the fitting by pressing on the tab indicated by arrow.
8. Pull the connection apart.

1. Apply a few drops of clean engine oil to the male connection end.
2. Push both sides of the quick-connect fitting together in order to cause the retaining feature 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-200372-S19996306352005102000000) .
2. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-200373-S09580687742005102000000) .
3. Remove the frame brace. Refer to «Frame Brace Replacement (TrailBlazer, Envoy, Bravada)»(ref-200388-S38628920842005102000000) or «Frame Brace Replacement (TrailBlazer EXT, Envoy XL)»(ref-200388-S40350629312005102000000) in Frame and Underbody.
4. Remove the fuel tank shield, if equipped. Refer to «Fuel Tank Shield Replacement (TrailBlazer, Envoy)»(ref-200388-S37284800062005102000000) or «Fuel Tank Shield Replacement (TrailBlazer EXT, Envoy XL)»(ref-200388-S31467977892005102000000) in Frame and Underbody.
5. Loosen the fuel hose clamp (1) at the fuel tank.
6. Separate the fuel hose (2) from the fuel tank.
7. Disconnect the fuel feed pipe (1) and evaporative emission (EVAP) pipe (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200373-S38404922092005102000000) .
8. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.
9. With the aid of an assistant, support the fuel tank.
10. Remove the fuel tank strap bolts (1).
11. Remove the fuel tank straps (2).
12. Carefully lower the fuel tank.
13. Disconnect the fuel tank pressure sensor electrical connector (4).
14. Disconnect the EVAP vent valve electrical connector (9).
15. Disconnect the fuel tank module (3) electrical connector.
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»(ref-200372-S27073207592005102000000) .

1. With the aid of an assistant, position and support the fuel tank.
2. Connect the fuel sender electrical connector (3).
3. Connect the fuel tank pressure sensor electrical connector (4).
4. Connect the EVAP vent valve electrical connector (9).
5. Install the fuel tank straps (2).
6. Install the fuel tank strap bolts (1). Tighten: Tighten the bolts to 32 N.m (24 lb ft).
7. Remove the caps from the fuel and EVAP pipes.
8. Connect the fuel feed pipe (1) and EVAP pipe (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200373-S38404922092005102000000) .
9. Connect the fuel hose (2) to the fuel tank. Tighten: Tighten the clamp (1) to 2.5 N.m (22 lb in).
10. Lower the vehicle.
11. Refill the fuel tank.
12. Install the fuel fill cap.
13. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000) in Engine Electrical.
14. 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.
15. Install the fuel tank shield, if equipped. Refer to «Fuel Tank Shield Replacement (TrailBlazer, Envoy)»(ref-200388-S37284800062005102000000) or «Fuel Tank Shield Replacement (TrailBlazer EXT, Envoy XL)»(ref-200388-S31467977892005102000000) in Frame and Underbody.
16. Install the frame brace. Refer to «Frame Brace Replacement (TrailBlazer, Envoy, Bravada)»(ref-200388-S38628920842005102000000) or «Frame Brace Replacement (TrailBlazer EXT, Envoy XL)»(ref-200388-S40350629312005102000000) in Frame and Underbody.
17. Lower the vehicle.

1. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief Procedure»(ref-200372-S19996306352005102000000) .
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
3. Remove the frame brace. Refer to «Frame Brace Replacement (TrailBlazer, Envoy, Bravada)»(ref-200388-S38628920842005102000000) or «Frame Brace Replacement (TrailBlazer EXT, Envoy XL)»(ref-200388-S40350629312005102000000) in Frame and Underbody.
4. Remove the fuel tank shield, if equipped. Refer to «Fuel Tank Shield Replacement (TrailBlazer, Envoy)»(ref-200388-S37284800062005102000000) or «Fuel Tank Shield Replacement (TrailBlazer EXT, Envoy XL)»(ref-200388-S31467977892005102000000) in Frame and Underbody.
5. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-200372-S37393191282005102000000) .
6. Disconnect the evaporative emission (EVAP) canister fresh air pipe. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200372-S03438683812005102000000) .
7. Disconnect the EVAP canister solenoid pipe. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200372-S03438683812005102000000) .
8. Disconnect the EVAP purge pipe. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200372-S03438683812005102000000) .
9. Disconnect the fuel filler pipe recirculation hose from the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200372-S03438683812005102000000) .
10. Loosen the clamp securing the fuel fill pipe to the fuel tank.
11. Disconnect the fuel fill pipe from the fuel tank.
12. Disconnect the fuel feed pipe (2) and EVAP pipe (1) from the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200372-S03438683812005102000000) .
13. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.
14. Support the fuel tank.
15. Remove the fuel tank strap attaching bolts.
16. Remove the fuel tank straps.
17. Carefully lower the fuel tank.
18. Disconnect the EVAP vent valve electrical connector (8).
19. Disconnect the fuel tank pressure sensor electrical connector (2).
20. Disconnect the fuel sender electrical connector (1).
21. Remove the fuel tank.
22. Place the fuel tank in a suitable work area.
23. If the fuel tank is not being replaced, go to «Installation Procedure»(ref-200372-S37518102522005102000000) .

1. Support the fuel tank.
2. Connect the fuel sender electrical connector (1).
3. Connect the EVAP vent valve electrical connector (2).
4. Connect the fuel pressure sensor electrical connector (8).
5. Install the fuel tank straps.
6. Install the fuel tank strap attaching bolts. Tighten: Tighten the bolts to 32 N.m (24 lb ft).
7. Remove the caps from the fuel and EVAP pipes.
8. Connect the fuel feed pipe (1) and the EVAP pipe (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200372-S03438683812005102000000) .
9. Connect the fuel fill pipe to the fuel tank. Tighten: Tighten the fuel fill hose clamp to 2.5 N.m (22 lb in).
10. Connect the fuel filler pipe recirculation hose to the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200372-S03438683812005102000000) .
11. Connect the EVAP purge pipe. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200372-S03438683812005102000000) .
12. Connect the EVAP canister solenoid pipe. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200372-S03438683812005102000000) .
13. Connect the EVAP canister fresh air pipe. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200372-S03438683812005102000000) .
14. Lower the vehicle.
15. Refill the fuel tank.
16. Install the fuel filler cap.
17. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000) in Engine Electrical.
18. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
19. Inspect for leaks. Turn ON the ignition, with the engine OFF for 10 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
20. Install the fuel tank shield, if equipped. Refer to «Fuel Tank Shield Replacement (TrailBlazer, Envoy)»(ref-200388-S37284800062005102000000) or «Fuel Tank Shield Replacement (TrailBlazer EXT, Envoy XL)»(ref-200388-S31467977892005102000000) in Frame and Underbody.
21. Install the frame brace. Refer to «Frame Brace Replacement (TrailBlazer, Envoy, Bravada)»(ref-200388-S38628920842005102000000) or «Frame Brace Replacement (TrailBlazer EXT, Envoy XL)»(ref-200388-S40350629312005102000000) in Frame and Underbody.
22. Lower the vehicle.

1. Remove the fuel tank. Refer to «Fuel Tank Replacement (TrailBlazer EXT, Envoy XL, Envoy XUV)»(ref-200372-S19443361222005102000000) or «Fuel Tank Replacement (TrailBlazer, Envoy, Rainier)»(ref-200372-S29464571742005102000000) .
2. Disconnect the fuel tank pressure harness connector.
3. Remove the fuel tank pressure sensor.

1. Install the new fuel tank pressure sensor seal.
2. Install the fuel tank pressure sensor.
3. Connect the fuel tank sensor harness connector.
4. Install the fuel tank. Refer to «Fuel Tank Replacement (TrailBlazer EXT, Envoy XL, Envoy XUV)»(ref-200372-S19443361222005102000000) or «Fuel Tank Replacement (TrailBlazer, Envoy, Rainier)»(ref-200372-S29464571742005102000000) .

1. Remove the fuel sender assembly. Refer to «Fuel Sender Assembly Replacement»(ref-200372-S24643162872005102000000) .
2. Disconnect the fuel pump electrical connector.
3. Remove the retaining clip from the fuel level sensor connector.
4. Disconnect the electrical connector from under the fuel sender cover.
5. Remove the sensor retaining clip.
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.
3. Connect the electrical connector to the fuel level sensor.
4. Install the retaining clip to the fuel level sensor electrical connector.
5. Connect the fuel pump electrical connector.
6. Install the fuel sender assembly. Refer to «Fuel Sender Assembly Replacement»(ref-200372-S24643162872005102000000) .

1. Remove the fuel tank. Refer to «Fuel Tank Replacement (TrailBlazer EXT, Envoy XL, Envoy XUV)»(ref-200372-S19443361222005102000000) or «Fuel Tank Replacement (TrailBlazer, Envoy, Rainier)»(ref-200372-S29464571742005102000000) .
2. Use the J 44402 to remove the fuel sender assembly retaining ring. See «Special Tools & Equipment»(ref-200372-S36410128202005102000000) .
3. 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.
4. 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. Use the J 44402 to install the fuel sender assembly retaining ring. See «Special Tools & Equipment»(ref-200372-S36410128202005102000000) .
4. Install the fuel tank. Refer to «Fuel Tank Replacement (TrailBlazer EXT, Envoy XL, Envoy XUV)»(ref-200372-S19443361222005102000000) or «Fuel Tank Replacement (TrailBlazer, Envoy, Rainier)»(ref-200372-S29464571742005102000000) .

Scheme 21

Scheme 22

1. Relieve the fuel pressure. Refer to «Fuel Pressure Relief Procedure»(ref-200372-S19996306352005102000000) .
2. Remove the powertrain control module (PCM) retaining bolts (3) and nuts (6).
3. Slide the PCM (1) off of the studs (5) and position the PCM out of the way.
4. Disconnect the engine coolant temperature sensor electrical connector (1).
5. Disconnect the fuel feed pipe (3) from the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-200372-S38494846302005102000000) .
6. Disconnect the evaporative emission (EVAP) purge pipe (1) from the EVAP canister purge valve.
7. Disconnect the integral clip (2) from the wire harness bracket.
8. Position the fuel feed pipe (3) above the PCM studs.
9. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
10. Use the following procedure with two wheel drive (2WD): Remove the transmission support. Refer to «Transmission Support Replacement»(ref-200388-S26539159952005102000000) in Frame and Underbody. Lower the transmission slightly. Remove the EVAP/fuel hose/pipe assembly retaining bolt (3) from the transmission. Disengage the EVAP/fuel hose/pipe assembly from the clip (1) at the rear of the transmission.
11. Use the following procedure with four wheel drive (4WD): Remove the transfer case. Refer to Transfer Case Assembly Replacement in Transfer Case - NVG 126-NP4. Remove the transmission support. Refer to «Transmission Support Replacement»(ref-200388-S26539159952005102000000) in Frame and Underbody. Lower the transmission slightly. Remove the EVAP/fuel hose/pipe assembly retaining bolt (3) from the transmission. Remove the EVAP/fuel hose/pipe assembly (2) from the clip at the rear of the transmission.
12. Remove the EVAP/fuel hose/pipe assembly (4) from the fuel pipe clip at the rear of the engine.
13. Disconnect the EVAP purge pipe at the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200372-S03438683812005102000000) .
14. Disconnect the chassis fuel feed pipe (1) from the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200372-S03438683812005102000000) .
15. Disconnect the chassis EVAP pipe (2) from the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200372-S03438683812005102000000) .
16. Remove the EVAP/fuel hose/pipe assembly from the vehicle.
17. Remove the fuel/EVAP hose/pipe assembly retaining clips.
18. Separate the fuel feed pipe (1) from the EVAP purge pipe (2).

1. Position the fuel feed pipe (1) to the EVAP purge pipe (2).
2. Install the EVAP/fuel hose/pipe assembly clips as noted during disassembly.
3. Position the EVAP/fuel hose/pipe assembly along the engine and transmission.
4. Connect the chassis fuel feed pipe (1) to the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200372-S03438683812005102000000) .
5. Connect the chassis EVAP purge pipe (2) to the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200372-S03438683812005102000000) .
6. Install the EVAP/fuel hose/pipe assembly (4) to the fuel pipe clip at the rear of the engine.
7. Use the following procedure with two wheel drive (2WD): Install the EVAP/fuel hose/pipe assembly into the clip (1) at the rear of the transmission. NOTE: Refer to «Fastener Notice»(ref-200361-S03298564292005102000000) in Cautions and Notices. Position the EVAP/fuel hose/pipe assembly against the transmission and install the retaining bolt (3) through the EVAP/fuel hose/pipe assembly strap into the transmission. Tighten: Tighten the bolt to 3.75 N.m (33 lb in). Raise the transmission to the normal installed position. Install the transmission support. Refer to «Transmission Support Replacement»(ref-200388-S26539159952005102000000) in Frame and Underbody.
8. Use the following procedure with four wheel drive (4WD): Install the EVAP/fuel hose/pipe assembly (2) into the clip at the rear of the transmission. Position the fuel EVAP/fuel hose/pipe assembly against the transmission and install the retaining bolt (3) through the EVAP/fuel hose/pipe assembly strap into the transmission. Tighten: Tighten the bolt to 3.75 N.m (33 lb in). Raise the transmission to the normal installed position. Install the transmission support. Refer to «Transmission Support Replacement»(ref-200388-S26539159952005102000000) in Frame and Underbody. Install the transfer case. Refer to Transfer Case Assembly Replacement in Transfer Case - NVG 126-NP4.
9. Lower the vehicle.
10. Connect the EVAP purge pipe (1) to the EVAP canister purge valve.
11. Connect the integral clip (2) to the wire harness bracket.
12. Connect the fuel feed pipe (3) to the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-200372-S38494846302005102000000) .
13. Connect the engine coolant temperature sensor electrical connector (1).
14. Install the PCM (1) onto the studs (5).
15. Install the PCM retaining bolts (3). Tighten: Tighten the bolts to 8 N.m (71 lb in).
16. Install the PCM retaining nuts (6). Tighten: Tighten the nuts to 8 N.m (71 lb in).
17. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000) in Engine Electrical.
18. 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.
19. Install the fuel tank shield, if equipped. Refer to «Fuel Tank Shield Replacement (TrailBlazer, Envoy)»(ref-200388-S37284800062005102000000) or «Fuel Tank Shield Replacement (TrailBlazer EXT, Envoy XL)»(ref-200388-S31467977892005102000000) in Frame and Underbody.

Note. Refer to Fuel and Evaporative Emission (EVAP) Hose/Pipe Connection Cleaning Notice in Cautions and Notices.

1. Remove the fuel tank. Refer to «Fuel Tank Replacement (TrailBlazer EXT, Envoy XL, Envoy XUV)»(ref-200372-S19443361222005102000000) or «Fuel Tank Replacement (TrailBlazer, Envoy, Rainier)»(ref-200372-S29464571742005102000000) .
2. Disconnect the fuel feed pipe from the fuel sender. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200372-S03438683812005102000000) .
3. Disconnect the fuel feed pipe from the fuel pipe retainer.
4. Remove the fuel feed pipe from the fuel tank.

1. Install the fuel feed pipe to the fuel tank.
2. Connect the fuel feed pipe to the fuel pipe retainer.
3. Connect the fuel feed pipe to the fuel sender. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200372-S03438683812005102000000) .
4. Install the fuel tank. Refer to «Fuel Tank Replacement (TrailBlazer EXT, Envoy XL, Envoy XUV)»(ref-200372-S19443361222005102000000) or «Fuel Tank Replacement (TrailBlazer, Envoy, Rainier)»(ref-200372-S29464571742005102000000) .

Note. Refer to Fuel and Evaporative Emission (EVAP) Hose/Pipe Connection Cleaning Notice in Cautions and Notices.

1. Remove the fuel tank. Refer to «Fuel Tank Replacement (TrailBlazer EXT, Envoy XL, Envoy XUV)»(ref-200372-S19443361222005102000000) or «Fuel Tank Replacement (TrailBlazer, Envoy, Rainier)»(ref-200372-S29464571742005102000000) .
2. Cut and remove the tie (2) securing the fuel feed pipe and EVAP canister purge pipe together.
3. Remove the fuel feed pipe (1) from the fuel sender module (4) and retaining clip (3). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200372-S03438683812005102000000) .

1. Install the fuel feed pipe (1) to the fuel sender module (4) and retaining clip (3). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200372-S03438683812005102000000) .
2. Install a new tie (2) securing the fuel feed pipe and EVAP canister purge pipe together.
3. Install the fuel tank. Refer to «Fuel Tank Replacement (TrailBlazer EXT, Envoy XL, Envoy XUV)»(ref-200372-S19443361222005102000000) or «Fuel Tank Replacement (TrailBlazer, Envoy, Rainier)»(ref-200372-S29464571742005102000000) .

1. Remove the fuel fill cap.
2. Remove the fuel fill pipe housing.
3. Remove the fuel fill pipe bracket nuts (2).
4. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
5. Remove the fuel fill pipe ground strap bolt (3).
6. Loosen the fuel fill hose clamp (8).
7. Separate the fuel hose (9) from the fuel fill pipe (7).
8. Cap the open end of the fuel fill hose (9).

1. Uncap the fuel fill pipe (9).
2. Install the fuel fill pipe (7). NOTE: Refer to «Fastener Notice»(ref-200361-S03298564292005102000000) in Cautions and Notices.
3. Connect the fuel fill hose (9) to the fuel fill pipe (7). Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
4. Install the fuel fill pipe ground strap bolt (3). Tighten: Tighten the bolt to 10 N.m (89 lb in).
5. Lower the vehicle.
6. Install the fuel fill pipe bracket nuts (2). Tighten: Tighten the nuts to 10 N.m (89 lb in).
7. Install the fuel fill pipe housing.
8. Install the fuel fill cap.

1. Remove the fuel fill cap.
2. Remove the fuel fill pipe housing.
3. Remove the fuel fill pipe bracket nuts (2).
4. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
5. Disconnect the fuel filler pipe recirculation hose from the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200372-S03438683812005102000000) .
6. Loosen the clamp securing the fuel fill pipe to the fuel tank.
7. Disconnect the fuel fill pipe from the fuel tank.
8. Cap the open end of the fuel fill hose.
9. Remove the fuel fill pipe ground strap bolt.
10. Remove the push-pin retainer and remove the fuel fill pipe from the vehicle frame.

1. Install the fuel fill pipe to the vehicle frame and install the push-pin retainer.
2. Install the fuel fill pipe ground strap bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
3. Uncap the fuel fill hose.
4. Connect the fuel fill pipe to the fuel tank. Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
5. Connect the fuel filler pipe recirculation hose to the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200372-S03438683812005102000000) .
6. Lower the vehicle.
7. Install the fuel fill pipe bracket nuts (2). Tighten: Tighten the nuts to 10 N.m (89 lb in).
8. Install the fuel fill pipe housing.
9. Install the fuel fill cap.

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-200372-S19996306352005102000000) .
2. Disconnect the fuel feed pipe (3) from the fuel rail (2). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-200372-S38494846302005102000000) .
3. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-200396-S00607332742005102000000) in Engine Mechanical.
4. Before removal, clean the fuel rail assembly and the cylinder head with a spray type engine cleaner, GM X-30A or equivalent, if necessary. Follow the package instructions. Do not soak the fuel rail in liquid cleaning solvent.
5. Disconnect the fuel injector harness in-line connector (3) from the engine wire harness.
6. Remove the fuel injector harness in-line connector (3) from the rocker cover.
7. Remove the fuel rail attaching bolts (2).
8. Remove the fuel rail assembly (1).
9. Remove the injector lower O-ring seal from the spray tip end of each injector.
10. Discard the O-ring seals.
11. If the fuel rail is not being replaced, go to «Installation Procedure»(ref-200372-S11916728402005102000000) .

1. Lubricate the new lower injector O-ring seals with clean engine oil.
2. Install the new O-ring seals on the spray tip end of each injector.
3. Install the fuel rail assembly (1).
4. Apply a 5 mm (0.2 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads of the fuel rail bolts (2). Install the fuel rail attaching bolts (2). Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Install the fuel injector harness in-line connector (3) to the rocker cover.
6. Connect the fuel injector harness in-line connector (3) to the engine wire harness.
7. Connect the fuel feed pipe (3) to the fuel rail (2). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-200372-S38494846302005102000000) .
8. Connect the fuel injector electrical connectors.
9. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-200396-S00607332742005102000000) in Engine Mechanical.
10. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000) in Engine Electrical.
11. 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.

1. Remove the fuel rail assembly. Refer to «Fuel Rail Assembly Replacement»(ref-200372-S41182972312005102000000) .
2. Disconnect the fuel injector electrical harness (2) connectors from the fuel injectors (4).
3. Remove the fuel injector retainer clips (6).
4. Remove the fuel injectors (4) from the fuel rail (1).
5. Discard the injector retainer clips (6).
6. Remove the injector O-ring seals (3,5) from both ends of the injectors (4). Discard the O-ring seals.

Scheme 23

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 fuel injector (3).
3. Install a new retainer clip (1) on the injector (3).
4. Push the fuel injectors (3) into the fuel rail (1) injector socket with the electrical connector facing outward. The retainer clip locks on to a flange on the fuel rail injector socket.
5. Connect the fuel injector electrical harness (2) connectors to the fuel injectors (3).
6. Install the fuel rail assembly (1). Refer to «Fuel Rail Assembly Replacement»(ref-200372-S41182972312005102000000) .

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
2. Disconnect the harness electrical connector (2) from the evaporative emission (EVAP) canister purge valve (1).
3. Disconnect the EVAP purge pipe from the EVAP canister purge valve.
4. Disconnect the engine vacuum pipe from the EVAP canister purge valve.
5. Remove the purge valve (2) from the purge valve mounting bracket.
6. If replacing the purge valve bracket, remove the attaching bolt (1) and purge valve bracket.

1. If replacing the purge bracket, install the purge valve bracket and the attaching bolt (1). Tighten: Tighten the purge valve mounting bracket attaching bolt to 10 N.m (89 lb in).
2. Install purge valve (2) on to the purge valve mounting bracket.
3. Connect the EVAP purge pipe to the EVAP canister purge valve.
4. Connect the engine vacuum pipe to the EVAP canister purge valve.
5. Connect the electrical harness connector (2) to the EVAP canister purge valve (1).
6. Lower the vehicle.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
2. Disconnect the harness connector (2) from the evaporative emission (EVAP) canister vent valve.
3. Disconnect the EVAP vent pipe (3) from the EVAP canister vent valve (1).
4. Disengage the bracket retaining tab (2) and remove the EVAP canister vent valve.

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

Note. Refer to Fuel and Evaporative Emission (EVAP) Hose/Pipe Connection Cleaning Notice in Cautions and Notices.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
2. Disconnect the EVAP canister purge pipe (1) from the EVAP canister and the fuel tank.
3. Disconnect the EVAP canister fresh air pipe (2) from the EVAP canister and the fuel tank.
4. Disconnect the EVAP canister vent solenoid valve pipe (3) from the EVAP canister and the vent solenoid valve.
5. Remove the pipes from the pipe retainer.

1. Install the pipes to the pipe retainer.
2. Connect the EVAP canister vent solenoid valve pipe (3) to the EVAP canister and the vent solenoid valve.
3. Connect the EVAP canister fresh air pipe (2) to the EVAP canister and the fuel tank.
4. Disconnect the EVAP canister purge pipe (1) from the EVAP canister and the fuel tank.
5. Lower the vehicle.

Note. Refer to Fuel and Evaporative Emission (EVAP) Hose/Pipe Connection Cleaning Notice in Cautions and Notices.

1. Remove the fuel tank. Refer to «Fuel Tank Replacement (TrailBlazer EXT, Envoy XL, Envoy XUV)»(ref-200372-S19443361222005102000000) or «Fuel Tank Replacement (TrailBlazer, Envoy, Rainier)»(ref-200372-S29464571742005102000000) .
2. Release the evaporative emission (EVAP) hose assembly retainers (1) from the fuel tank heat shield.
3. Cut and remove the ties (1) securing the EVAP hoses.
4. Disconnect the EVAP hose assembly (3) from the fuel tank vent valves and fuel module.
5. Remove the EVAP hose assembly from the fuel tank.
6. Remove the EVAP canister purge pipe (2) from the fuel tank.

1. Install the EVAP canister purge pipe (2) to the fuel tank.
2. Install the EVAP hose assembly to the fuel tank.
3. Connect the EVAP hose assembly (3) to the fuel tank vent valves and fuel module.
4. Install new ties (1) securing the EVAP hoses.
5. Attach the EVAP hose assembly retainers (1) to the fuel tank heat shield.
6. Install the fuel tank. Refer to «Fuel Tank Replacement (TrailBlazer EXT, Envoy XL, Envoy XUV)»(ref-200372-S19443361222005102000000) or «Fuel Tank Replacement (TrailBlazer, Envoy, Rainier)»(ref-200372-S29464571742005102000000) .

Note. Refer to Fuel and Evaporative Emission (EVAP) Hose/Pipe Connection Cleaning Notice in Cautions and Notices.

1. Remove the fuel tank. Refer to «Fuel Tank Replacement (TrailBlazer EXT, Envoy XL, Envoy XUV)»(ref-200372-S19443361222005102000000) or «Fuel Tank Replacement (TrailBlazer, Envoy, Rainier)»(ref-200372-S29464571742005102000000) .
2. Release the evaporative emission (EVAP) hose assembly retainers (1) from the fuel tank heat shield.
3. Disconnect the EVAP solenoid pipe (3) from the vent solenoid valve and the EVAP canister.
4. Remove the EVAP solenoid pipe (3) from the fuel tank.
5. Disconnect the EVAP pipe assembly (2) from the fuel tank vent valves, the fuel module, and the EVAP canister.
6. Remove the EVAP pipe assembly (2) from the fuel tank.
7. Disconnect the EVAP canister purge pipe (1) from the EVAP canister and retaining clip.
8. Remove the EVAP canister purge pipe (1) from the fuel tank.

1. Install the EVAP canister purge pipe (1) to the fuel tank.
2. Connect the EVAP canister purge pipe (1) to the EVAP canister and retaining clip.
3. Install the EVAP pipe assembly (2) to the fuel tank.
4. Connect the EVAP pipe assembly (2) to the fuel tank vent valves, the fuel module, and the EVAP canister.
5. Install the EVAP solenoid pipe (3) to the fuel tank.
6. Connect the EVAP solenoid pipe (3) to the vent solenoid valve and the EVAP canister.
7. Attach the EVAP hose assembly retainers (1) to the fuel tank heat shield.
8. Install the fuel tank. Refer to «Fuel Tank Replacement (TrailBlazer EXT, Envoy XL, Envoy XUV)»(ref-200372-S19443361222005102000000) or «Fuel Tank Replacement (TrailBlazer, Envoy, Rainier)»(ref-200372-S29464571742005102000000) .

1. Remove the evaporative emission (EVAP)/fuel hose/pipe assembly. Refer to «Fuel Hose/Pipes Replacement - Chassis»(ref-200372-S28745224792005102000000) .
2. Remove the fuel/EVAP hose/pipe assembly retaining clips.
3. Separate the EVAP purge pipe (2) from the fuel pipe (1).

1. Position the new EVAP purge pipe (2) to the fuel pipe (1).
2. Install the EVAP/fuel hose/pipe assembly clips as noted during disassembly.
3. Install the EVAP/fuel hose/pipe assembly. Refer to «Fuel Hose/Pipes Replacement - Chassis»(ref-200372-S28745224792005102000000) .

1. Remove the spare tire. Reference the owners manual for additional information if needed.
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
3. Disconnect the evaporative emission (EVAP) vapor pipe (1) from the EVAP canister.
4. Disconnect the EVAP purge pipe (2) from the EVAP canister.
5. Disconnect the EVAP vent pipe (3) from the EVAP canister.
6. Remove the bolts (1) from the EVAP mounting bracket (2).
7. Remove the EVAP canister and bracket assembly from the vehicle.
8. Remove the bolt (1) attaching the EVAP canister (3) to the mounting bracket (2).
9. Remove the EVAP canister (3) from the mounting bracket (2).
10. Remove the EVAP retaining bracket (2) from the EVAP canister (3) by releasing the retaining bracket clip (1) from the EVAP canister (3).

1. Install the EVAP retaining bracket (2) to the EVAP canister (3) ensuring the retaining bracket clip (1) is fully engaged.
2. Install the EVAP canister (3) to the mounting bracket (2).
3. Install the bolt (1) attaching the EVAP canister (3) to the mounting bracket (2). Tighten: Tighten the bolt to 20 N.m (15 lb ft).
4. Install the EVAP canister and bracket assembly to the vehicle.
5. Install the bolts (1) to the EVAP mounting bracket (2). Tighten: Tighten the bolts to 20 N.m (15 lb ft).
6. Connect the evaporative emission (EVAP) vapor pipe (1) to the EVAP canister.
7. Connect the EVAP purge pipe (2) to the EVAP canister.
8. Connect the EVAP vent pipe (3) to the EVAP canister.
9. Lower the vehicle.
10. Install the spare tire. Reference the owners manual for additional information if needed.

1. Remove the fuel tank. Refer to «Fuel Tank Replacement (TrailBlazer EXT, Envoy XL, Envoy XUV)»(ref-200372-S19443361222005102000000) or «Fuel Tank Replacement (TrailBlazer, Envoy, Rainier)»(ref-200372-S29464571742005102000000) .
2. Disconnect the evaporative emission (EVAP) vapor pipe (2) from the EVAP canister.
3. Disconnect the EVAP vent pipe (1) from the EVAP canister.
4. Disconnect the EVAP purge pipe from the EVAP canister. The purge pipe is the small pipe next to the vapor pipe (2).
5. 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.
6. Pry the canister away from the tabs as indicated in the illustration.
7. 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 2 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 (TrailBlazer EXT, Envoy XL, Envoy XUV)»(ref-200372-S19443361222005102000000) or «Fuel Tank Replacement (TrailBlazer, Envoy, Rainier)»(ref-200372-S29464571742005102000000) .

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-200372-S19209944462005102000000) .
2. Disconnect the ignition coil connectors (1) from the ignition coils.
3. Remove the retaining bolts (2) from the ignition coils.
4. Remove the ignition coils (1) from the engine.

1. Install the ignition coil (1).
2. Install the ignition coil retaining bolts (2). Tighten: Tighten the ignition coil retaining bolts to 10 N.m (89 lb in).
3. Replace the ignition coil connectors (1).
4. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-200372-S19209944462005102000000) .

1. Turn OFF the ignition switch.
2. Remove the ignition coils. Refer to «Ignition Coil(s) Replacement»(ref-200372-S31037551202005102000000) .
3. Remove the spark plugs from the engine.

1. Measure the spark plug gap on the spark plugs to be installed. Compare the measurement to the gap specifications. Refer to «Ignition System Specifications»(ref-200372-S24765872602005102000000) . Correct as necessary.
2. Install the spark plugs to the engine. Tighten: Tighten the spark plugs to 18 N.m (13 lb ft).
3. Install the ignition coils. Refer to «Ignition Coil(s) Replacement»(ref-200372-S31037551202005102000000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
2. Disconnect the crankshaft position (CKP) sensor harness connector.
3. Remove the CKP sensor retaining bolt.
4. Remove the CKP sensor from the engine block.

1. Any wear
2. Any cracks
3. Any leakage

Replace the O-ring if necessary. Lubricate the new 0-ring with engine oil before installation.

1. Install the CKP sensor into the engine block. Tighten: Tighten the bolt to 10 N.m (89 lb in).
2. Install the CKP sensor retaining bolt.
3. Connect the CKP sensor harness connector.
4. Lower the vehicle.
5. Perform the «CKP System Variation Learn Procedure»(ref-200372-S14520124782005102000000) .

1. Remove the camshaft position (CMP) sensor electrical connector (1).
2. Remove the CMP sensor retaining bolt.

1. Install the camshaft position (CMP) sensor. Tighten: Tighten the CMP sensor bolt to 10 N.m (89 lb in).
2. Install the CMP sensor electrical connector (1).

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-200396-S20666880032005102000000) in Engine Mechanical.
2. Remove the 3 power steering pump bolts and move the pump out of the way. Refer to «Power Steering Pump Replacement (4.2L)»(ref-200416-S40545325892005102000000) or «Power Steering Pump Replacement (5.3L)»(ref-200416-S12863791602005102000000) in Power Steering Systems.
3. Disconnect the camshaft position actuator solenoid electrical connector.
4. Remove the camshaft position actuator solenoid retaining bolt (3).
5. Remove the camshaft position actuator solenoid (2) from the engine block.
6. Clean debris from the hole (1).

1. Install a new O-ring on the camshaft position actuator solenoid.
2. Lubricate the hole (1) with engine oil.
3. Install the camshaft position actuator solenoid (2) and bolt (3). Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Connect the camshaft position actuator solenoid electrical connector.
5. Install the power steering pump and bolts. Refer to «Power Steering Pump Replacement (4.2L)»(ref-200416-S40545325892005102000000) or «Power Steering Pump Replacement (5.3L)»(ref-200416-S12863791602005102000000) in Power Steering Systems.
6. Install the drive belt. Refer to «Drive Belt Replacement»(ref-200396-S20666880032005102000000) in Engine Mechanical.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
2. Remove the knock sensor harness connector (4).
3. Remove the knock sensor retaining bolt (3).
4. Remove the appropriate knock sensor (1 or 2).

1. Install the knock sensor (1 or 2) and the bolt (3). Tighten: Tighten the sensor to 25 N.m (18 lb ft).
2. Connect the knock sensor harness connector (4).
3. Lower the vehicle.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
2. Disconnect both the air inlet and air outlet pipes from the secondary air injection (AIR) reaction pump.
3. Remove the electrical relay from the AIR pump bracket.
4. Disconnect the electrical connector from the AIR pump.
5. Remove the 3 bolts securing the AIR pump bracket to the vehicle frame.
6. Remove the AIR pump from the vehicle.

1. Install the AIR pump to the vehicle.
2. Install the 3 bolts securing the AIR pump bracket to the vehicle frame. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
3. Connect the electrical connector to the AIR pump.
4. Install the electrical relay to the AIR pump bracket.
5. Connect both the air inlet and air outlet pipe to the AIR pump.
6. Lower the vehicle.

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-200372-S36504693382005102000000) .
2. Disconnect the electrical connector from the secondary air injection (AIR) reaction solenoid valve.
3. Disconnect the AIR pump air outlet pipe from the AIR solenoid valve.
4. Remove the nut (1) securing the transmission fluid level indicator tube (2) to the AIR solenoid valve.
5. Remove the transmission fluid level indicator tube (2) from the AIR solenoid valve stud (3).
6. Remove the 2 AIR solenoid valve studs (3).
7. Remove the AIR solenoid valve (4) and the gasket (5) from the engine.

1. Install the AIR solenoid valve (4) and the gasket (5) to the engine.
2. Install the 2 AIR solenoid valve studs (3). Tighten: Tighten the studs to 25 N.m (18 lb ft).
3. Install the transmission fluid level indicator tube (2) to the AIR solenoid valve stud (3).
4. Install the nut (1) securing the transmission fluid level indicator tube (2) to the AIR solenoid valve. Tighten: Tighten the nut to 10 N.m (89 lb in).
5. Connect the AIR pump air outlet pipe to the AIR solenoid valve.
6. Connect the electrical connector to the AIR solenoid valve.
7. Install the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-200372-S36504693382005102000000) .

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
2. Disconnect both the air inlet and air outlet pipe from the secondary air injection reaction (AIR) pump.
3. Lower the vehicle.
4. Remove the cylinder head. Refer to «Cylinder Head Replacement»(ref-200396-S03232749552005102000000) in Engine Mechanical - 4.2L.
5. Remove the bolt and fir-tree fasteners securing the AIR pipe to the cylinder head.

1. Install the bolt and fir-tree fasteners securing the AIR pipe to the cylinder head. Tighten: Tighten the bolt to 10 N.m (89 lb in).
2. Install the cylinder head. Refer to «Cylinder Head Replacement»(ref-200396-S03232749552005102000000) in Engine Mechanical - 4.2L.
3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
4. Connect both the air inlet and air outlet pipe to the AIR pump.
5. Lower the vehicle.

1. Remove the radiator support diagonal brace if applicable. Refer to «Brace Replacement - Radiator Support Diagonal»(ref-200376-S25454043242005102000000) in Body Front End.
2. Disconnect the secondary air injection (AIR) reaction pump inlet hose from the air cleaner air outlet duct.
3. Loosen the 3 air cleaner housing retaining screws (1).
4. Remove the air cleaner housing (2).
5. Lift the air cleaner element (6) and air outlet duct (3) from the lower air cleaner housing/washer solvent tank assembly (4).
6. Remove the air cleaner element (6) from the air outlet duct (3) with a twisting and pulling motion.
7. Inspect the entire assembly for dust, debris, or water. Clean or replace as necessary.

1. Install the air cleaner element (6) onto the air outlet duct (3) with a twisting and pushing motion.
2. Install the air cleaner element (6) and air outlet duct (3) into the lower air cleaner housing/washer solvent tank assembly (4).
3. Install the air cleaner housing (2). Tighten: Tighten the 3 air cleaner housing retaining screws (1) to 4 N.m (35 lb in).
4. Connect the AIR pump inlet hose to the air cleaner air outlet duct.
5. Install the radiator support diagonal brace if applicable. Refer to «Brace Replacement - Radiator Support Diagonal»(ref-200376-S25454043242005102000000) in Body Front End.

1. Remove the air cleaner cover/resonator (2) then position the air cleaner element (6) and air outlet duct (3) out of the way. Refer to «Air Cleaner Element Replacement»(ref-200372-S42673670352005102000000) .
2. Remove the air inlet duct (5) from the lower air cleaner housing/washer solvent tank assembly (4).
3. Disconnect the following electrical connectors: Windshield washer pump (1) Headlamp washer pump (2), if equipped Low solvent level sensor (4) Lift gate washer pump (6), if equipped
4. Remove the washer solvent level sensor wire harness from the wire harness retaining clips (3, 5).
5. If applicable, disconnect the headlamp washer hose from the headlamp washer pump located on the lower air cleaner housing/washer solvent tank. Cap the headlamp washer pump outlet fitting to prevent loss of washer solvent.
6. Disconnect the washer pump hoses (3) and plug the washer pump outlet ports to prevent loss of washer solvent.
7. Remove the 2 air cleaner housing/washer solvent tank assembly retaining nuts (1) from the mounting studs.
8. Lift the lower air filter housing/washer solvent tank assembly (2) off of the studs and remove the assembly.

1. Install the lower air filter housing/washer solvent tank assembly (2) onto the mounting studs.
2. Connect the washer pump hoses (3) to the washer pumps.
3. Install the 2 air cleaner housing/washer solvent tank assembly retaining nuts (1) to the mounting studs. Tighten: Tighten the nuts to 15 N.m (11 lb ft).
4. If applicable, Connect the headlamp washer hose to the headlamp washer pump located on the lower air cleaner housing/washer solvent tank.
5. Connect the following electrical connectors: Windshield washer pump (1) Headlamp washer pump (2), if equipped Low solvent level sensor (4) Lift gate washer pump (6), if equipped
6. Install the washer solvent level sensor wire harness to the wire harness retaining clips (3, 5).
7. Install the air inlet duct (5) to the lower air cleaner housing/washer solvent tank assembly (4).
8. Install the air cleaner element (6) and air outlet duct (3) to the lower air cleaner housing/washer solvent tank assembly.
9. Install the air cleaner cover/resonator (2). Refer to «Air Cleaner Element Replacement»(ref-200372-S42673670352005102000000) .

1. Loosen the air cleaner outlet duct and air cleaner outlet resonator clamps (2).
2. Disconnect the air cleaner outlet duct from the air cleaner outlet resonator (3).
3. Remove the 2 air cleaner outlet resonator to engine bolts (4).
4. Disconnect the crankcase ventilation hose (1) from the valve cover port (2).
5. Disconnect the electrical connector to the intake air temperature (IAT) sensor.
6. Remove the air cleaner outlet resonator assembly (5) from the engine.

1. Connect the electrical connector to the IAT sensor.
2. 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). The air cleaner outlet resonator (5) is properly fit to the throttle body assembly.
3. Install the 2 air cleaner outlet resonator to engine bolts (4). Tighten: Tighten the resonator to engine bolts to 6 N.m (53 lb in).
4. Connect the air cleaner outlet duct to the air cleaner outlet resonator (3).
5. Properly position the air cleaner outlet duct and air cleaner outlet resonator clamps (2). Tighten: Tighten the clamps (2) to 4 N.m (35 lb in).

1. Remove the air cleaner element. Refer to «Air Cleaner Element Replacement»(ref-200372-S42673670352005102000000) .
2. Disconnect the electrical connector from the intake air temperature (IAT) sensor (1).
3. Loosen the air cleaner outlet duct clamp (2) on the air cleaner side of the air cleaner outlet resonator (3).
4. Remove the air cleaner outlet duct.
5. If replacing the air cleaner outlet duct, remove the IAT sensor. Refer to «Intake Air Temperature (IAT) Sensor Replacement»(ref-200372-S37230729882005102000000) .

1. If the IAT sensor was previously removed, install the IAT sensor into the air cleaner outlet duct. Refer to «Intake Air Temperature (IAT) Sensor Replacement»(ref-200372-S37230729882005102000000) .
2. Install the air cleaner outlet duct onto the air cleaner outlet resonator (3).
3. Install the air cleaner element. Refer to «Air Cleaner Element Replacement»(ref-200372-S42673670352005102000000) .
4. Properly position the air cleaner outlet duct clamp (2) on the air cleaner side of the air cleaner outlet resonator (3). Tighten: Tighten the clamp (2) to 4 N.m (35 lb in).
5. Connect the electrical connector to the IAT sensor (1).