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Engine Control System - 5.3L - Introduction: Removal & Installation GMC Envoy II

Testing & Diagnostics 2 illustrations ~8261 words

Engine Control Module (ECM) Replacement

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

Removal Procedure

  1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life.
  2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000) in Engine Electrical.
  3. Disconnect the cooling fan electrical connector for additional clearance while removing the ECM.
  4. Depress the ECM/transmission control module (TCM) cover retainers (2).
  5. Remove the ECM/TCM cover from the ECM/TCM bracket (1).
  6. Disconnect the ECM electrical connectors (2) from the ECM (1)
  7. Release the bracket ECM retainers (1).
  8. Tilt the ECM (2) away from the ECM/TCM bracket.
  9. Remove the ECM (2) from the ECM bracket (1).
  10. Only when replacement of the ECM/TCM bracket (2) is necessary, remove the TCM (1). Refer to «Transmission Control Module (TCM) Replacement»(ref-200406-S23837347222005102000000) in Automatic Transmission - 4L60-E/4L65-E.
  11. Remove the ECM/TCM bracket retaining bolts (2).
  12. Remove the ECM/TCM bracket (1) from the vehicle frame.

Installation Procedure

  1. If the ECM/TCM bracket (1) was previously removed, install the ECM/TCM bracket (1) to the vehicle frame.
  2. Install the ECM/TCM bracket retaining bolts (2).
  3. Tighten the ECM/TCM bracket bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  4. If the TCM was previously removed from the ECM/TCM bracket (2), install the TCM (1). Refer to «Transmission Control Module (TCM) Replacement»(ref-200406-S23837347222005102000000) in Automatic Transmission - 4L60-E/4L65-E.
  5. Insert the ECM (2) into the retaining slots of the ECM/TCM bracket (1).
  6. Secure the ECM (2) to the ECM/TCM mounting bracket ensuring the ECM retaining tabs (1) are fully engaged.
  7. Connect the ECM electrical connectors (2) to the ECM (1) if previously removed.
  8. Install the ECM/TCM cover (2) to the ECM/TCM bracket (1).
  9. Ensure the ECM/TCM cover retainers (2) are fully engaged with the ECM/TCM bracket (1).
  10. Connect the cooling fan electrical connector.
  11. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000) in Engine Electrical.
  12. If the ECM was replaced the replacement ECM must be programmed. Refer to «Control Module References»(ref-200358-S22779820132005102000000) in Computer/Integrating Systems.
  1. Turn OFF the ignition.
  2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
  3. Drain the cooling system 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. Lower the vehicle.
  5. Disconnect the engine coolant temperature (ECT) sensor electrical connector (1).
  6. Remove the ECT sensor.
  1. Coat the ECT sensor threads with sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent.
  2. Install the ECT sensor. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
  3. Connect the ECT sensor electrical connector (1).
  4. 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.
IMPORTANTUse care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation.
  1. Disconnect the MAF/IAT sensor electrical connector.
  2. Loosen the clamps at the MAF/IAT sensor and the throttle body.
  3. Remove the air cleaner outlet duct bolt.
  4. Remove the air cleaner outlet duct.
  5. Loosen the clamp attaching the MAF/IAT sensor to the air cleaner housing.
  6. Remove the MAF/IAT sensor from the air cleaner housing.
IMPORTANTThe embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine.
  1. Locate the air flow direction arrow (2) on the MAF/IAT sensor.
  2. Install the MAF/IAT sensor on to the air cleaner housing.
  3. Tighten the clamp securing the MAF/IAT sensor to the air cleaner housing. Tighten: Tighten the clamp to 7 N.m (62 lb in).
  4. Install the air cleaner outlet duct.
  5. Install the air cleaner outlet duct bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  6. Tighten the clamps at the MAF/IAT sensor and the throttle body. Tighten: Tighten the clamps to 7 N.m (62 lb in).
  7. Connect the MAF/IAT electrical connector.
  1. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (3).
  2. Remove the MAP sensor retaining clip (2) from the intake manifold.
  3. Remove the MAP sensor (1) from the intake manifold.
IMPORTANTLightly coat the MAP sensor seal with clean engine oil before installing the sensor.
  1. Install the MAP sensor (1). Push the MAP sensor into the intake manifold.
  2. Install the MAP sensor retainer (2) to the intake manifold.
  3. Connect the MAP sensor electrical connector (3).
  1. Disconnect the electrical connector from the brake booster vacuum sensor.
  2. Remove the brake booster vacuum sensor (1) from the vacuum brake booster.
  3. Remove the brake booster vacuum sensor grommet (2) from the vacuum brake booster.
  1. Install the brake booster vacuum sensor grommet (2) to the vacuum brake booster.
  2. Install the brake booster vacuum sensor (1) to the vacuum brake booster.
  3. Connect the electrical connector to the brake booster vacuum sensor.
  1. Unscrew the heated oxygen sensor (HO2S) sensor from the catalytic converter.
  2. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (4.2L Engine)»(ref-200436-S36189290182005102000000) or «Catalytic Converter Replacement (5.3L Engine)»(ref-200436-S10814057632005102000000) in Engine Exhaust.
  3. Remove the connector position assurance (CPA) retainer.
  4. Disconnect the heated oxygen sensor (HO2S) electrical connector (3).
  1. Connect the HO2S electrical connector (3).
  2. Install the CPA retainer.
  3. Install the catalytic converter. Refer to «Catalytic Converter Replacement (4.2L Engine)»(ref-200436-S36189290182005102000000) or «Catalytic Converter Replacement (5.3L Engine)»(ref-200436-S10814057632005102000000) in Engine Exhaust.
  4. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
  5. Install the HO2S (2). Tighten: Tighten the sensor to 42 N.m (31 lb ft).
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
  2. Remove the connector position assurance (CPA) retainer.
  3. Disconnect the heated oxygen sensor (HO2S) electrical connector.
  4. Remove the HO2S (2).
IMPORTANTA special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation.
  1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
  2. Install the HO2S (2). Tighten: Tighten the sensor to 42 N.m (31 lb ft).
  3. Connect the HO2S electrical connector.
  4. Install the CPA retainer.
  5. Lower the vehicle.
  1. Unscrew the heated oxygen sensor (HO2S) sensor from the catalytic converter.
  2. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (4.2L Engine)»(ref-200436-S36189290182005102000000) or «Catalytic Converter Replacement (5.3L Engine)»(ref-200436-S10814057632005102000000) in Engine Exhaust.
  3. Remove the connector position assurance (CPA) retainer.
  4. Disconnect the heated oxygen sensor (HO2S) electrical connector (2).
  1. Connect the HO2S electrical connector (2).
  2. Install the CPA retainer.
  3. Install the catalytic converter. Refer to «Catalytic Converter Replacement (4.2L Engine)»(ref-200436-S36189290182005102000000) or «Catalytic Converter Replacement (5.3L Engine)»(ref-200436-S10814057632005102000000) in Engine Exhaust.
  4. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
  5. Install the HO2S (2). Tighten: Tighten the sensor to 42 N.m (31 lb ft).
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
  2. Remove the connector position assurance (CPA) retainer.
  3. Disconnect the heated oxygen sensor (HO2S) electrical connector (1).
  4. Remove the HO2S (2).
  1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
  2. Install the HO2S (2). Tighten: Tighten the sensor to 42 N.m (31 lb ft).
  3. Connect the HO2S electrical connector (1).
  4. Install the CPA retainer.
  5. Lower the vehicle.
  1. Disconnect the accelerator pedal position (APP) sensor electrical connector.
  2. Remove the 3 APP sensor bolts (1).
  3. Remove the APP sensor (2).
  1. Install the APP sensor.
  2. Install the 3 APP sensor bolts (1). Tighten: Tighten the bolts to 20 N.m (15 lb ft).
  3. Connect the APP sensor electrical connector.
  4. Verify that the vehicle meets the following conditions: The vehicle is not in a reduced engine power mode. The ignition is ON. The engine is OFF.
  5. Connect a scan tool in order to test for a proper throttle-opening and throttle-closing range.
  6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle.
  1. Partially drain the cooling system in order to allow the hose at the throttle body to be removed. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) in Engine Cooling.
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-200373-S04937318252005102000000) .
  3. Disconnect the throttle actuator motor electrical connector (1) from the throttle actuator motor (2).
  4. Reposition the throttle body hose clamp.
  5. Remove both of the throttle body engine coolant hoses from the throttle body.
  6. Remove the throttle body bolts.
  7. Remove the throttle body and gasket. Discard the gasket (1).
  1. Install a NEW throttle body gasket (1).
  2. Install the throttle body.
  3. Install the throttle body bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  4. Connect the 2 throttle body engine coolant hoses to the throttle body.
  5. Position the throttle body hose clamps.
  6. Connect the throttle actuator motor electrical connector (1) to the throttle actuator motor (2).
  7. Install the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-200373-S04937318252005102000000) .
  8. Refill the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) in Engine Cooling.
  9. Verify that the vehicle meets the following conditions: The vehicle is not in a reduced engine power mode. The ignition is ON. The engine is OFF.
  10. Connect a scan tool in order to test for a proper throttle-opening and throttle-closing range.
  11. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT).
  12. Start the engine.
  13. Inspect for coolant leaks.
  1. Remove the bleed hose on the J 34730-1A from the approved container.
  2. Remove the shop towel from around the fuel pressure service connection and discard into an approved container.
  3. Disconnect the J 34730-1A from the fuel pressure service connection.
  4. install the fuel pressure service connection cap.
  5. Inspect for leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-200373-S15552554882005102000000) .
  2. Remove the retainers from the fuel line quick-connect fittings.
  3. Using compressed air, blow any dirt or debris from around the fittings.
  4. Using the correct tool from J 41769 , insert the tool into the female connector, then push inward in order to release the quick connect locking tabs.
  5. Pull the fuel line connection apart.
  6. Use a clean shop towel in order to wipe off the male connection end.
  7. Inspect both ends of the fittings for dirt and burrs. Clean or replace the components as required.
CAUTIONIn order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.
  1. Apply a few drops of clean engine oil to the male connection end.
  2. Push both sides of the fittings together in order to snap the retaining tabs into place.
  3. Once installed, pull on both sides of the connection in order to make sure the connection is secure.
  4. Install the retainers to the fuel line quick-connect fittings.
  5. Install the fuel cap.
  6. Connect the negative battery cable. Refer to Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000) in Engine Electrical.
CAUTIONRefer to Gasoline/Gasoline Vapors Caution in Cautions and Notices.

Scheme 99

Scheme 99
Scheme 99
IMPORTANTThere are several types of Plastic Collar Fuel and Evaporative Emission Quick Connect Fittings used on this vehicle. Bartholomew (1) Q Release (2) Squeeze to Release (3) Sliding Retainer (4) Push Down TI (5) The following instructions apply to all of these types of Plastic Collar Quick Connect Fittings except where indicated.
  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 Release Tab 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 doesn't 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. 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 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.
  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 the Installation Procedure.
  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 sensor electrical connector.
  3. Remove the fuel tank pressure sensor.
  1. Install the fuel tank pressure sensor.
  2. Connect the fuel tank pressure sensor electrical connector.
  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 sender assembly. Refer to «Fuel Sender Assembly Replacement»(ref-200373-S23845607092005102000000) .
  2. Disconnect the fuel level sensor electrical connector (1).
  3. Depress the fuel level sensor retaining tabs (2) to release the sensor from the sender assembly.
  4. Remove the fuel level sensor electrical connector (1) and sensor (2) from the fuel sender assembly.
  1. Install the fuel level sensor (2) and electrical connector (1) to the fuel sender assembly.
  2. Connect the fuel level sensor electrical connector (1).
  3. Ensure the fuel level sensor retaining tabs (2) are fully engaged.
  4. Install the fuel sender assembly. Refer to «Fuel Sender Assembly Replacement»(ref-200373-S23845607092005102000000) .
  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. Remove the fuel feed (1) and EVAP (2) lines from the fuel sender assembly. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200373-S38404922092005102000000) .
  3. Using J 44402 , remove the fuel sender lock ring (1).
  4. Remove the fuel sender assembly (2) and seal (3). Discard the seal.
  5. Clean the fuel sender sealing surfaces (4).
  1. Install a NEW seal (3) onto the fuel tank.
  2. Install the fuel sender assembly (2).
  3. Using J 44402 , install the fuel sender lock ring (1).
  4. Install the fuel feed (1) and EVAP (2) lines to the sender assembly. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200373-S38404922092005102000000) .
  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. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-200373-S15552554882005102000000) .
  2. Disconnect the fuel feed pipe (3) at the fuel rail (2). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-200373-S11470256792005102000000) .
  3. Disconnect the EVAP canister purge pipe (1, 4). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200373-S38404922092005102000000) .
  4. Cap the fuel rail and EVAP pipes in order to prevent possible contamination of the EVAP/fuel system.
  5. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
  6. Remove the nuts securing the left catalytic converter to the exhaust manifold.
  7. Remove the nuts securing the right catalytic converter to the exhaust manifold.
  8. Lower the catalytic converter assembly until it rests on the vehicle frame.
  9. Use the following procedure if the vehicle is equipped with 2-wheel drive (2WD): Support the transmission with a suitable transmission jack. 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 from the retaining clips (1) on the transmission.
  10. Use the following procedure if the vehicle is equipped with 4-wheel drive (4WD): Remove the front propeller shaft. Refer to «Propeller Shaft Replacement - Front»(ref-200422-S39219319742005102000000) in Propeller Shaft. Remove the transfer case. Refer to Transfer Case Assembly Replacement in Transfer Case - NVG 126-NP4. Support the transmission with a suitable transmission jack. 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 from the retaining clips (1) on the transmission.
  11. Remove the EVAP/fuel hose/pipe bracket nut (5).
  12. Remove the fuel hose/pipe bracket (6) from the bellhousing stud.
  13. Disconnect the EVAP pipe (2) from the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200373-S38404922092005102000000) .
  14. Disconnect the fuel feed pipe (1) from the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200373-S38404922092005102000000) .
  15. Cap the fuel and EVAP pipes at the fuel tank.
  16. Remove the EVAP/fuel hose/pipe assembly from the vehicle.
  17. Remove the EVAP/fuel hose/pipe assembly retaining clips.
  18. Remove the fuel feed or return pipe to be replaced from the EVAP/fuel hose/pipe assembly.
  1. Install the fuel feed or return pipe to the EVAP/fuel hose/pipe assembly.
  2. Install the EVAP/fuel hose/pipe assembly retaining clips.
  3. Install the EVAP/fuel hose/pipe assembly to the vehicle.
  4. Remove the caps from the fuel filter and pipes at the fuel tank.
  5. Connect the EVAP pipe (2) to the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200373-S38404922092005102000000) .
  6. Connect the fuel feed pipe (1) to the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200373-S38404922092005102000000) .
  7. Install the EVAP/fuel hose/pipe bracket (6) to the bellhousing stud.
  8. Install the EVAP/fuel hose/pipe bracket nut (5). Tighten: Tighten the nut to 10 N.m (89 lb in).
  9. Use the following procedure if the vehicle is equipped with 4WD: Install the EVAP/fuel hose/pipe assembly to the retaining clips (1) on the transmission. Raise the transmission to the normal installed height. Install the transmission support. Refer to «Transmission Support Replacement»(ref-200388-S26539159952005102000000) in Frame and Underbody. Remove the transmission jack. Install the transfer case. Refer to Transfer Case Assembly Replacement in Transfer Case - NVG 126-NP4. Install the front propeller shaft. Refer to «Propeller Shaft Replacement - Front»(ref-200422-S39219319742005102000000) in Propeller Shaft.
  10. Use the following procedure if the vehicle is equipped with 2WD: Install the EVAP/fuel hose/pipe assembly to the retaining clips (1) on the transmission. Raise the transmission to the normal installed height. Install the transmission support. Refer to «Transmission Support Replacement»(ref-200388-S26539159952005102000000) in Frame and Underbody. Remove the transmission jack.
  11. Install the nuts securing the right catalytic converter to the exhaust manifold. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
  12. Install the nuts securing the left catalytic converter to the exhaust manifold. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
  13. Lower the vehicle.
  14. Remove the caps from the fuel rail and EVAP pipes.
  15. Connect the EVAP canister purge pipe (1,4). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200373-S38404922092005102000000)
  16. Connect the fuel feed pipe (3) at the fuel rail (2). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-200373-S11470256792005102000000) .
  17. Install the fuel fill cap.
  18. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000) in Engine Electrical.
  19. Use the following procedure to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for leaks.
CAUTIONRefer to Fuel and EVAP Pipe Caution in Cautions and Notices.
CAUTIONRefer to Gasoline/Gasoline Vapors Caution in Cautions and Notices.

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-200373-S38404922092005102000000) .
  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-200373-S38404922092005102000000) .
  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) .
CAUTIONRefer to Fuel and EVAP Pipe Caution in Cautions and Notices.
CAUTIONRefer to Gasoline/Gasoline Vapors Caution in Cautions and Notices.

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 retaining clip (3).
  4. Disconnect the fuel feed pipe (1) from the fuel sender module (4). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200373-S38404922092005102000000) .
  1. Connect the fuel feed pipe (1) to the fuel sender module (4). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200373-S38404922092005102000000) .
  2. Install the fuel feed pipe (1) to the retaining clip (3).
  3. Install a new tie (2) securing the fuel feed pipe and EVAP canister purge pipe together.
  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) .
IMPORTANTAn eight-digit identification number is located on the fuel rail. Refer to this model identification number if servicing or part replacement is required.
  1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-200373-S04937318252005102000000) .
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-200373-S15552554882005102000000) .
  3. Remove the positive crankcase ventilation (PCV) foul air hose.
  4. Disconnect the air conditioning (A/C) compressor pressure switch electrical connector (2).
  5. Remove the wire harness from the clip (1) on the cylinder head.
  6. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1).
  7. Disconnect the generator electrical connector.
  8. Disconnect the following electrical connectors on the right hand side of the engine: Coil main electrical harness (1) Electronic throttle control (ETC) (2) Fuel injectors (3)
  9. Perform the following steps in order to disconnect the fuel injector electrical connectors. Mark the connectors to their corresponding injectors to ensure correct reassembly. Pull the connector position assurance (CPA) retainer (2) on the connector up 1 click. Push the tab (1) on the connector in. Disconnect the fuel injector electrical connector. Repeat the steps for each injector electrical connector.
  10. Remove the electrical harness from the clips on ignition coil bracket.
  11. Disconnect the following electrical connectors on the left hand side of the engine: The evaporative emission (EVAP) purge solenoid (1) The knock sensor (2) The manifold absolute pressure (MAP) sensor (3) The main coil (5) The fuel injectors (4)
  12. Remove the electrical harness from the clips on ignition coil bracket.
  13. Remove the upper engine wire harness retainer nut (1).
  14. Reposition the upper engine wire harness aside.
  15. Disconnect the fuel feed pipe (1) from the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-200373-S11470256792005102000000) .
  16. Remove the EVAP canister purge solenoid from the fuel rail. Refer to «Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement»(ref-200373-S13315643892005102000000) .
  17. Remove the fuel rail bolts (2 and 3).
  18. Loosen but do not remove the fuel rail crossover pipe retainer clip screws.
  19. Remove the fuel rail assembly (1).
  20. Remove the fuel injector lower O-ring seal (4) from each injector, if necessary.
  21. Discard the O-ring seals.
  22. If the fuel rail is not being replaced, go to the Installation Procedure.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-200373-S15552554882005102000000) .
  2. Remove the fuel rail crossover pipe retaining clip screws (1) and retainer clips (2).
  3. Remove the crossover pipe (3) from the left and right hand fuel rails.
  4. Remove and discard the crossover fuel pipe O-rings (4).
  1. Lubricate the NEW fuel rail crossover pipe O-rings (4) with clean engine oil.
  2. Install the NEW fuel rail crossover pipe O-rings (4) onto the crossover pipe (3).
  3. Install the fuel rail crossover pipe (3) to the left and right hand fuel rails.
  4. Install the fuel rail crossover pipe retainer clips (2).
  5. install the fuel rail retainer clip screws (1). Tighten: Tighten the screws to 3.8 N.m (34 lb in).
  6. Install the fuel fill cap.
  7. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000) in Engine Electrical.
  8. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn OFF the ignition OFF for 10 seconds. Turn ON the ignition ON, with the engine OFF. Inspect for fuel leaks.
  1. Remove the fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-200373-S42922616492005102000000) .
  2. Remove and discard the fuel injector retainer clip (4).
  3. Remove the fuel injector (2).
  4. Remove and discard the fuel injector O-ring seals (1 and 3).

Scheme 100

Scheme 100: Installation Procedure
Scheme 100: Installation Procedure
IMPORTANTWhen ordering new fuel injectors, you must order the correct injector for the application being serviced.

The fuel injector (1) is stamped with a identification part number (2). A 4-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 and 4) with clean engine oil.
  2. Install the NEW injector O-ring seals (2 and 4) onto the injector (3).
  3. Install a NEW retainer clip (1) on the injector (3).
  4. Push the fuel injector into the fuel rail injector socket with the electrical connector facing outward. The retainer clip locks on to a flange on the fuel rail injector socket.
  5. Install the fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-200373-S42922616492005102000000) .
  1. Disconnect the EVAP pipes (1 and 2) from the EVAP purge solenoid. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200373-S38404922092005102000000) .
  2. Disconnect the EVAP purge solenoid electrical connector.
  3. Remove the EVAP purge solenoid (1) from the fuel rail.
  1. Install the EVAP purge solenoid (1) to the fuel rail.
  2. Connect the EVAP purge solenoid electrical connector.
  3. Connect the EVAP pipes (1 and 2) to the EVAP purge solenoid. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200373-S38404922092005102000000) .
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
  2. Disconnect the evaporative emission (EVAP) canister vent valve electrical connector (2).
  3. Disconnect the EVAP vent pipe from the canister vent valve.
  4. Disengage the bracket retaining tab and remove the EVAP canister vent valve.
  1. Install the EVAP canister vent valve onto the bracket.
  2. Inspect for proper retention of the EVAP vent valve on the bracket.
  3. Connect the EVAP vent pipe to the EVAP canister vent valve.
  4. Connect the EVAP canister vent valve electrical connector (2).
  5. Lower the vehicle.
IMPORTANTClean the tube connections and surrounding areas before disconnecting in order to avoid possible evaporative emission (EVAP) system contamination.
  1. Disconnect the EVAP pipe (1) from the intake manifold and the EVAP canister purge solenoid. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200373-S38404922092005102000000) .
  2. Disconnect the EVAP pipe (2) from the EVAP canister purge solenoid and the chassis EVAP pipe. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200373-S38404922092005102000000) .
  3. Cap the Intake manifold port, the EVAP canister purge solenoid and the chassis EVAP pipe in order to prevent possible EVAP system contamination.
  1. Remove the caps from the Intake manifold port, the EVAP canister purge solenoid and the chassis EVAP pipe.
  2. Connect the EVAP pipe (2) to the EVAP canister purge solenoid and the chassis EVAP pipe. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200373-S38404922092005102000000) .
  3. Connect the EVAP pipe (1) to the intake manifold and the EVAP canister purge solenoid. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200373-S38404922092005102000000) .
CAUTIONRefer to Fuel and EVAP Pipe Caution in Cautions and Notices.

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.
  1. Remove the evaporative emission (EVAP)/fuel hose/pipe assembly. Refer to «Fuel Hose/Pipes Replacement - Chassis»(ref-200373-S27650331182005102000000) .
  2. Remove the EVAP purge pipe (1) from the fuel hose/pipe (2).
  1. Install the EVAP purge pipe (1) to the fuel hose/pipe (2).
  2. Install the EVAP/fuel hose/pipe assembly. Refer to «Fuel Hose/Pipes Replacement - Chassis»(ref-200373-S27650331182005102000000) .
CAUTIONRefer to Fuel and EVAP Pipe Caution in Cautions and Notices.

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) .
CAUTIONRefer to Fuel and EVAP Pipe Caution in Cautions and Notices.

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. Remove the EVAP canister purge pipe (1) from the retaining clip.
  8. Disconnect the EVAP canister purge pipe (1) from the EVAP canister.
  9. 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.
  3. Install the EVAP canister purge pipe (1) to the retaining clip.
  4. Install the EVAP pipe assembly (2) to the fuel tank.
  5. Connect the EVAP pipe assembly (2) to the fuel tank vent valves, the fuel module, and the EVAP canister.
  6. Install the EVAP solenoid pipe (3) to the fuel tank.
  7. Connect the EVAP solenoid pipe (3) to the vent solenoid valve and the EVAP canister.
  8. Attach the EVAP hose assembly retainers (1) to the fuel tank heat shield.
  9. 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 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 two tab side. Ensure the tabs have completely engaged.
  2. Connect the EVAP purge pipe to the EVAP canister. The purge pipe is the small pipe next to the vapor pipe (2).
  3. Connect the EVAP vent pipe (1) to the EVAP canister.
  4. Connect the EVAP vapor pipe (2) to the EVAP canister.
  5. Install the fuel tank. Refer to «Fuel Tank Replacement (TrailBlazer EXT, Envoy XL, Envoy XUV)»(ref-200372-S19443361222005102000000) or «Fuel Tank Replacement (TrailBlazer, Envoy, Rainier)»(ref-200372-S29464571742005102000000) .
  1. Remove the spark plug wire from the ignition coil.
  2. Disconnect the ignition coil electrical connector.
  3. Remove the ignition coil bolts.
  4. Remove the ignition coil.
  1. Install the ignition coil.
  2. Install the ignition coil bolts. Tighten: Tighten the bolts to 8 N.m (71 lb in).
  3. Connect the ignition coil electrical connector.
  4. Connect the spark plug wire to the ignition coil.
  1. Remove the spark plug wire from the spark plug. Twist each spark plug 1/2 turn. Pull only on the boot in order to remove the wire from each spark plug.
  2. Remove the spark plug wire from the ignition coil. Twist each spark plug boot 1/2 turn. Pull only on the boot in order to remove the wires from the ignition coil.
  1. Install the spark plug wire to the ignition coil.
  2. Install the spark plug wire to the spark plug.
  3. Inspect the wires for proper installation: Push sideways on each boot in order to inspect the seating. Reinstall any loose boot.
  1. Remove the spark plug wire. Refer to «Spark Plug Wire Replacement»(ref-200373-S01328868302005102000000) .
  2. Remove the washer solvent container to gain access to the #2 spark plug. Refer to «Washer Solvent Container Replacement (Envoy, TrailBlazer)»(ref-200389-S19089800582005102000000) or «Washer Solvent Container Replacement (Rainier)»(ref-200389-S14905152262005102000000) in Wiper/Washer Systems.
  3. Loosen the spark plug 1-2 turns.
  4. Brush or using compressed air, blow away any dirt from around the spark plug.
  5. Remove the spark plug. If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number.
  1. Correctly position the spark plug washer.
  2. Inspect the spark plug gap. Adjust the gap as needed. Specification: Spark plug gap: 1.524 mm (0.060 in)
  3. Hand start the spark plug in the corresponding cylinder.
  4. Tighten the spark plug. Tighten: For used heads, tighten the plug to 15 N.m (11 lb ft). For NEW heads, tighten the plug to 20 N.m (15 lb ft).
  5. Install the spark plug wire. Refer to «Spark Plug Wire Replacement»(ref-200373-S01328868302005102000000) .
  6. If removed, install the washer solvent container. Refer to «Washer Solvent Container Replacement (Envoy, TrailBlazer)»(ref-200389-S19089800582005102000000) or «Washer Solvent Container Replacement (Rainier)»(ref-200389-S14905152262005102000000) in Wiper/Washer Systems.
  1. Remove the starter. Refer to «Starter Motor Replacement (4.2L Engine)»(ref-200375-S09518058692005102000000) or «Starter Motor Replacement (5.3L Engine)»(ref-200375-S38723987142005102000000) in Engine Electrical.
  2. Disconnect the electrical connector (2) from the CKP sensor (1).
  3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine.
  4. Remove the CKP sensor bolt.
  5. Remove the CKP sensor.
  1. Install the CKP sensor.
  2. Install the CKP sensor bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  3. Connect the electrical connector (2) to the CKP sensor (1).
  4. Install the starter. Refer to «Starter Motor Replacement (4.2L Engine)»(ref-200375-S09518058692005102000000) or «Starter Motor Replacement (5.3L Engine)»(ref-200375-S38723987142005102000000) in Engine Electrical.
  1. Remove the generator bracket assembly. Refer to «Generator Bracket Replacement (5.3L Engine)»(ref-200375-S25472433142005102000000) in Engine Electrical.
  2. Remove the camshaft position sensor mounting bolts (1).
  3. Remove the camshaft position sensor assembly (4, 5, 6) from the front cover (7).
  4. Disconnect the camshaft position sensor jumper harness (2) and the engine harness (3) electrical connectors.
  5. Remove the camshaft sensor assembly (4, 5, 6).
  6. Disconnect camshaft position sensor (5) from the jumper harness (4).
  1. Reconnect the camshaft sensor (5) and the jumper harness (4).
  2. Install the O-ring (6) on the camshaft sensor assembly (4 and 5).
  3. Reconnect the camshaft position sensor assembly (4, 5 and 6) and the engine harness connector (3).
  4. Install the camshaft position sensor assembly (4, 5 and 6) in the front cover (7).
  5. Install the camshaft position sensor mounting bolts. Tighten: Tighten the camshaft position mounting bolts 25 N.m (18 lb ft).
  6. Install the generator assembly. Refer to «Generator Bracket Replacement (5.3L Engine)»(ref-200375-S25472433142005102000000) in Engine Electrical.
  1. Remove the mounting bolt for the knock sensor 1.
  2. Disconnect the electrical connector of the knock sensor from the engine harness (3).
  3. Remove the knock sensor (2) from the engine block (4).
  1. Reconnect the engine harness (3) and the knock sensor (2) electrical connectors.
  2. Position the knock sensor 2 on the engine block (4).
  3. Install the mounting bolt (1) for the knock sensor 2.
  4. Tighten the knock sensor mounting bolt (1). Tighten: Tighten the knock sensor mounting bolt to 20 N.m (15 lb ft).
  1. Disconnect the electrical connector (3) from the knock sensor (2).
  2. Remove the knock sensor bolt (1).
  3. Remove the knock sensor (2) from the engine block.
  1. Position the knock sensor (2) on the engine block.
  2. Install the knock sensor bolt (1). Tighten: Tighten the bolt (1) to 20 N.m (15 lb ft).
  3. Connect the electrical connector (3) to the knock sensor (2).
  1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-200373-S04937318252005102000000) .
  2. Disconnect the mass air flow (MAF) /intake air temperature (IAT) sensor electrical connector (1).
  3. Remove the radiator support diagonal brace. Refer to «Brace Replacement - Radiator Support Diagonal»(ref-200376-S25454043242005102000000) in Body Front End.
  4. Loosen the 4 air cleaner cover retaining screws (1).
  5. Remove the air cleaner housing cover (2). Lift and rotate the cover in order to remove the cover from the vehicle.
  6. Remove the air filter element (6) and the MAF/IAT sensor (3) from the lower air cleaner housing/washer solvent tank assembly (4).
  7. Separate the air filter element (6) from the MAF/IAT sensor (3).
  8. Inspect the entire assembly for dust, debris, or water. Clean or replace as necessary.
  1. Install the MAF/IAT sensor (3) to the air filter element (6).
  2. Install the air filter element (6) and MAF/IAT sensor (3) to the lower air cleaner housing/washer solvent tank assembly (4).
  3. Install the air cleaner cover (2) and secure with 4 retaining screws (1). Tighten: Tighten the screws to 4 N.m (35 lb in).
  4. Install the radiator support diagonal brace. Refer to «Brace Replacement - Radiator Support Diagonal»(ref-200376-S25454043242005102000000) in Body Front End.
  5. Connect the MAF/IAT sensor electrical connector (1).
  6. Install the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-200373-S04937318252005102000000) .
  1. Remove the following components from the lower air cleaner housing/washer solvent tank assembly (4). Refer to «Air Cleaner Element Replacement»(ref-200373-S07810391472005102000000) . The air cleaner cover (2) The filter element (6) The mass air flow (MAF) /intake air temperature (IAT) sensor (3) The air inlet duct (5)
  2. Disconnect the following electrical connectors: The windshield washer pump (1) The headlamp washer pump (2), if equipped The low solvent level sensor (4) The lift gate washer pump (6), if equipped
  3. Remove the wire harness to the washer solvent level sensor from the retaining clips (3,5).
  4. 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.
  5. Disconnect the washer pump hoses (3) and plug the outlet ports to prevent loss of washer solvent.
  6. Remove the 2 retaining nuts (1) from the mounting studs on the air cleaner housing/washer solvent tank assembly.
  7. 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 retaining nuts (1) to the mounting studs on the air cleaner housing/washer solvent tank assembly. Tighten: Tighten the nuts to 15 N.m (11 lb ft).
  4. If applicable, connect the washer hose to the headlamp washer pump located on the lower air cleaner housing/washer solvent tank.
  5. Connect the following electrical connectors: The windshield washer pump (1) The headlamp washer pump (2) The low solvent level sensor (4) The lift gate washer pump (6)
  6. Install the wire harness for the washer solvent level sensor to the wire harness retaining clips (3,5).
  7. Install the following components to the lower air cleaner housing/washer solvent tank assembly (4). Refer to «Air Cleaner Element Replacement»(ref-200373-S07810391472005102000000) . The air cleaner cover (2) The filter element (6) The mass air flow (MAF) /intake air temperature (IAT) sensor (3) The air inlet duct (5)
  1. Disconnect the positive crankcase ventilation (PCV) fresh air tube (2) from the air cleaner resonator outlet duct (1).
  2. Loosen the clamps at the following: Mass air flow (MAF)/intake air temperature (IAT) sensor Throttle body
  3. Remove the air cleaner outlet duct bolt.
  4. Remove the air cleaner outlet duct.
  1. Install the air cleaner outlet duct.
  2. Install the air cleaner outlet duct bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  3. Tighten the clamps at the following: MAF/IAT sensor Throttle body Tighten: Tighten the clamps to 7 N.m (62 lb in).
  4. Connect the PCV fresh air tube (2) to the air cleaner resonator outlet duct (1).

More articles — Engine Control System - 5.3L - Introduction