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Engine Control System - 4.3L (Introduction): Removal & Installation GMC Savana G2500

Testing & Diagnostics 1 illustration ~11531 words

Powertrain Control Module (PCM) Replacement

Note. Turn the ignition OFF when installing or removing the PCM connectors and disconnecting or reconnecting the power to the PCM (battery cable, PCM pigtail, PCM fuse, jumper cables, etc.) in order to prevent internal PCM damage.

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.

IMPORTANTRemove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM.
IMPORTANTThe replacement PCM 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-186595-S11053284922005083000000) in Engine Electrical.
  3. Disconnect the PCM harness connectors.
  4. Release the spring latch from the PCM.
  5. Lift the PCM from the PCM mounting tray.
  6. Remove the PCM from the engine compartment.

Installation Procedure

  1. Install the PCM to the PCM mounting tray.
  2. Secure the spring latch to the PCM.
  3. Connect the PCM connectors to the PCM. Tighten: Tighten the PCM connector end fasteners to 8 N.m (71 lb in).
  4. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-186595-S11053284922005083000000) in Engine Electrical.
  5. If a new PCM is being installed, program the PCM. Refer to «Service Programming System (SPS)»(ref-186602-S21168727172005083000000) in Programming.

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

  1. Turn OFF the ignition.
  2. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  3. Drain the coolant below the level of the ECT sensor. Refer to «Draining and Filling Cooling System»(ref-186629-S37766623502005083000000) in Engine Cooling.
  4. Disconnect the electrical connector.
  5. Carefully remove the ECT sensor.

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

  1. Coat the threads with sealer GM P/N 9985253 or equivalent.
  2. Install the ECT sensor. Tighten: Tighten the ECT sensor to 20 N.m (15 lb ft).
  3. Connect the ECT sensor harness connector to the ECT sensor.
  4. Refill the cooling system. Refer to «Draining and Filling Cooling System»(ref-186629-S37766623502005083000000) in Engine Cooling.
  5. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  1. Turn OFF the ignition.
  2. Disconnect the mass air flow (MAF) sensor harness connector.
  3. Loosen the clamps (1) on the MAF sensor.
  4. Carefully remove the MAF sensor from the air intake ducts (5).
  1. Install the MAF sensor (5) into the air intake ducts.
  2. Tighten the clamps (1) on the MAF sensor. Tighten: Tighten the clamps to 4 N.m (35 lb in).
  3. Connect the MAF sensor harness connector.

Other than checking for a worn grommet and loose electrical connectors, the only service possible is a unit replacement if the diagnosis shows a malfunctioning manifold absolute pressure (MAP) sensor.

  1. Turn OFF the ignition.
  2. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  3. Disconnect the MAP sensor harness connector.
  4. Remove the MAP sensor by pulling straight up with a slight rocking motion.
  5. Remove the MAP sensor grommet.
  6. Discard the MAP sensor grommet.
  1. Install the new MAP sensor grommet on the MAP sensor.
  2. Install the MAP sensor.
  3. Connect the MAP sensor harness connector.
  4. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  2. Disconnect the connector (1) for the HO2S.
  3. Remove the HO2S (2) using a J 39194-B .
  1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary.
  2. Install the HO2S (2) using a J 39194-B . Tighten: Tighten the sensor to 42 N.m (31 lb ft).
  3. Connect the HO2S harness connector (1).
  4. Lower the vehicle.
  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  2. Disconnect the connector (1) from the HO2S.
  3. Remove the HO2S (2) using a J 39194-B .
  1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary.
  2. Install the HO2S (2) using a J 39194-B . Tighten: Tighten the sensor to 42 N.m (31 lb ft).
  3. Connect the HO2S harness connector (1).
  4. Lower the vehicle.
  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  2. Disconnect the connector (1) for the HO2S.
  3. Remove the HO2S (2) using a J 39194-B .
  1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary.
  2. Install the HO2S (2) using a J 39194-B . Tighten: Tighten the sensor to 42 N.m (31 lb ft).
  3. Connect the HO2S harness connector (1).
  4. Lower the vehicle.
  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  2. Disconnect the connector (1) for the HO2S.
  3. Remove the HO2S (2) using a J 39194-B .
  1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary.
  2. Install the HO2S (2) using a J 39194-B . Tighten: Tighten the sensor to 42 N.m (31 lb ft).
  3. Connect the HO2S harness connector (1).
  4. Lower the vehicle.
  1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  2. Remove the throttle position (TP) sensor harness connector.
  3. Remove the TP sensor attaching fasteners.
  4. Remove the TP sensor from the throttle body assembly.
  1. With the throttle valve closed, install the TP sensor on the throttle shaft. Rotate the TP sensor counterclockwise in order to align the mounting holes.
  2. Install the TP sensor attaching fasteners. Tighten: Tighten the fasteners to 2 N.m (18 lb in).
  3. Install the TP sensor harness connector.
  4. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  1. Turn OFF the ignition.
  2. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  3. Disconnect the harness connector from the idle air control (IAC) valve.
  4. Remove the IAC valve attaching fasteners.
  5. Remove the IAC valve assembly.
  6. Remove the O-ring.
  1. Measure the distance between tip of the IAC valve pintle and the mounting flange. If the distance is more than 28 mm (1.10 in), use finger pressure in order to slowly retract the pintle. The force required to retract the pintle of a new valve will not cause damage to the valve.
  2. Lubricate the IAC valve O-ring with clean engine oil.
  3. Install the IAC valve assembly.
  4. Install the attaching fasteners. Tighten: Tighten the IAC valve fasteners to 3 N.m (27 lb in).
  5. Connect the IAC harness connector.
  6. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  7. Reset the IAC valve pintle position.
  1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  2. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-186616-S40473932682005083000000) .
  3. Remove the accelerator cable from the throttle lever.
  4. Remove the accelerator cable from the engine cable bracket.
  5. Remove the accelerator cable from the accelerator pedal (2).
  6. Remove the accelerator cable from the bulkhead (1).
  1. Install the accelerator cable to the bulkhead (1).
  2. Install the accelerator cable to the accelerator pedal (2).
  3. Install the accelerator cable to the engine cable bracket.
  4. Install the accelerator cable to the throttle lever.
  5. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-186616-S40473932682005083000000) .
  6. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  1. Lift upward on the accelerator pedal (3) to relieve the tension on the cable (2).
  2. Remove the retainer (1) from the pedal lever (4) hole.
  3. Remove the cable from the slot in the pedal lever.
  4. Remove the accelerator pedal mounting fasteners.
  5. Remove the accelerator pedal assembly.
IMPORTANTThe accelerator cable is not to be kinked or damaged in any way during installation. Ensure that the mounting surface between the accelerator pedal assembly and the dash panel is free of insulation. The carpet and padding in the pedal area must be positioned to lay flat and free of wrinkles and bunches. Wires, hoses, cables, and other flexible components should not be within 13 mm (0.52 in) of the cable or lever, at any point in their travel.
  1. Place the accelerator pedal assembly (4) on the mounting surface.
  2. Install the mounting bolts. Tighten: Tighten the pedal assembly to 5 N.m (44 lb in).
  3. Lift upward on the accelerator pedal (3).
  4. Insert the cable (2) through the pedal lever slot.
  5. Press the retainer (1) into the lever hole until fully seated.
  6. Check the pedal (3) for free movement by pressing down on the pedal.
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-186595-S11053284922005083000000) in Engine Electrical.
  2. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  3. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-186616-S40473932682005083000000) .
  4. Remove the air cleaner outlet adapter stud.
  5. Remove the cruise control cable. Refer to «Cruise Control Cable Replacement»(ref-186606-S27581933252005083000000) in Cruise Control.
  6. Remove the accelerator cable. Refer to «Accelerator Controls Cable Replacement»(ref-186616-S35683245022005083000000) .
  7. Remove the stud and nuts retaining the accelerator control cable bracket and position the bracket aside.
  8. Disconnect the idle air control (IAC) valve harness connector.
  9. Disconnect the throttle position (TP) sensor harness connector.
  10. Remove the throttle body retaining studs.
  11. Remove the throttle body assembly.
  12. Discard the throttle body seal.
  1. Clean the gasket surface on the intake manifold.
  2. Install the throttle body assembly with a new seal.
  3. Install the throttle body assembly retaining studs. Tighten: Tighten the studs to 9 N.m (80 lb in).
  4. Install the adapter stud for the air cleaner outlet resonator. Tighten: Tighten the fasteners to 8 N.m (71 lb in).
  5. Connect the TP sensor harness connector.
  6. Connect the IAC valve harness connector.
  7. Install the accelerator control cable bracket using the mounting fasteners. Tighten: Tighten the fasteners to 12 N.m (106 lb in).
  8. Install the accelerator cable.
  9. Install the cruise control cable.
  10. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-186616-S40473932682005083000000) .
  11. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  12. Connect the negative battery cable.
  13. Use the following procedure in order to inspect the accelerator pedal operation. Depress the pedal to the floor. Release the accelerator pedal.
CAUTIONGasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
  1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  2. Install the J 34730-1A fuel pressure gage to the fuel pressure service connection. See «Special Tools & Equipment»(ref-186616-S38154004832005083000000) .
  3. Turn ON the ignition.
  4. Place the bleed hose of the fuel pressure gage into an approved gasoline container.
  5. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage.
  6. Command the fuel pump ON with a scan tool.
  7. Close the bleed valve on the fuel pressure gage.
  8. Inspect for fuel leaks.
  1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure.
  2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. See «Special Tools & Equipment»(ref-186616-S38154004832005083000000) .
  3. Remove the J 34730-1A from the fuel pressure connection. See «Special Tools & Equipment»(ref-186616-S38154004832005083000000) .
  4. Drain any fuel remaining in the fuel pressure gage into an approved container.
  5. Inspect for leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
  6. Install the cap on the fuel pressure connection.
  7. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to «Fuel Pressure Relief Procedure»(ref-186616-S33408734262005083000000) .
  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 J 37088-A tool set for the size of the fitting. See «Special Tools & Equipment»(ref-186616-S38154004832005083000000) . Insert the tool into the female connector, then push inward to release the locking tabs.
  5. Pull the connection apart.
  6. Using a clean shop towel, 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 to cause the retaining tabs to snap into place.
  3. Once installed, pull on both sides of the fitting to make sure the connection is secure.
  4. Install the retainer to the quick-connect fitting.
  1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the «Fuel Pressure Relief Procedure»(ref-186616-S33408734262005083000000) .
  2. Using compressed air, blow any dirt out of the quick-connect fitting.
  3. Squeeze the plastic retainer release tabs.
  4. Pull the connection apart.
  1. Apply a few drops of clean engine oil to the male fuel pipe end.
  2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs to snap into place.
  3. Once installed, pull on both sides of the quick-connect fitting in order to make sure the connection is secure.
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-186616-S33408734262005083000000) .
  3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  4. Clean all the fuel filter connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
  5. Disconnect the fuel feed pipe from the fuel filter outlet.
  6. Disconnect the fuel feed pipe from the fuel filter inlet.
  7. Cap the fuel pipes in order to prevent fuel system contamination.
  8. Remove the fuel filter from the bracket.
  9. Inspect the fuel pipe O-rings for cuts, nicks, swelling, or distortion. Replace the O-rings if necessary.
  1. Install the fuel filter into the bracket.
  2. Remove the caps from the fuel pipes.
  3. Connect the fuel feed pipe to the fuel filter inlet.
  4. Connect the fuel feed pipe to the fuel filter outlet.
  5. Lower the vehicle.
  6. Tighten the fuel filler cap.
  7. Connect the negative battery cable.
  8. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  1. Disconnect the negative battery cable.
  2. Remove the mounting bolts from the EVAP canister bracket.
  3. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-186616-S33408734262005083000000) .
  4. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  5. Clean all the fuel filter connections and the surrounding areas before disconnecting the fuel pipes in order to avoid contamination of the fuel system.
  6. Disconnect the fuel feed pipe from the fuel filter outlet.
  7. Disconnect the fuel feed pipe from the fuel filter inlet.
  8. Cap the fuel pipes in order to prevent fuel system contamination.
  9. Remove the fuel filter from the bracket.
  10. Inspect the fuel pipe O-rings for cuts, nicks, swelling, or distortion. Replace the O-rings if necessary.
  1. Install the fuel filter into the bracket.
  2. Remove the caps from the fuel pipes.
  3. Connect the fuel feed pipe to the fuel filter inlet.
  4. Connect the fuel feed pipe to the fuel filter outlet.
  5. Install the mounting bolts to the EVAP canister bracket. Tighten: Tighten the bolts to 12 N.m (106 lb in).
  6. Lower the vehicle.
  7. Tighten the fuel filler cap.
  8. Connect the negative battery cable.
  9. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-186616-S33408734262005083000000) .
  3. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-186616-S26971635402005083000000) .
  4. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  5. Clean all fuel pipe and hose connections and surrounding areas before disconnecting the fuel pipes in order to avoid contamination of the fuel system.
  6. Loosen the fuel fill hose clamp.
  7. Disconnect the fuel fill hose from the fuel fill pipe.
  8. Disconnect the rear evaporative emission (EVAP) pipe at the EVAP canister.
  9. With the aid of an assistant, support the fuel tank.
  10. Remove the attaching bolts (1) from the fuel tank strap.
  11. Remove the fuel tank straps (2).
  12. Carefully lower the fuel tank.
  13. Disconnect the fuel feed pipe and the fuel return pipe at the fuel sender. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-186616-S14431155502005083000000) .
  14. Disconnect the electrical connectors from the fuel sender and the fuel pressure sensor.
  15. Remove the fuel tank.
  16. Place the fuel tank in a suitable work area.
  17. Cap the open fuel and EVAP pipes on the vehicle in order to prevent possible fuel system contamination.
  18. Remove the EVAP pipe from the roll over valves and the retainer clips.
  19. Remove the fuel sender assembly from the fuel tank. Refer to «Fuel Sender Assembly Replacement»(ref-186616-S31826379002005083000000) .
  20. Remove the fuel fill hose from the fuel tank.
  1. Install the fuel tank insulators (6).
  2. Remove the caps from the fuel and EVAP pipes.
  3. Install the fuel fill hose to the fuel tank. Tighten: Tighten the fuel fill hose clamp to 2.75 N.m (24 lb in).
  4. Install the fuel sender assembly to the fuel tank. Refer to «Fuel Sender Assembly Replacement»(ref-186616-S31826379002005083000000) .
  5. Connect the EVAP pipe to the roll-over valves and the retainer clips.
  6. With the aid of an assistant, position and support the fuel tank.
  7. Raise the fuel tank slightly.
  8. Connect the electrical connectors to the fuel sender and the fuel pressure sensor.
  9. Connect the fuel feed pipe and the fuel return pipe to the fuel sender. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-186616-S14431155502005083000000) .
  10. Raise the tank fully.
  11. Install the fuel tank straps (2).
  12. Install the new attaching bolts (1) to the fuel tank strap. Tighten: Tighten the fuel tank strap attaching bolts to 20.5 N.m (15 lb ft).
  13. Connect the rear EVAP pipe (1) to the EVAP canister.
  14. Connect the fuel fill hose to the fuel fill pipe. Tighten: Tighten the fuel fill hose clamp to 2.75 N.m (24 lb in).
  15. Lower the vehicle.
  16. Refill the fuel tank.
  17. Tighten the fuel filler cap.
  18. Connect the negative battery cable.
  19. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-186616-S33408734262005083000000) .
  3. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-186616-S26971635402005083000000) .
  4. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  5. Loosen the fuel fill hose clamp.
  6. Disconnect the fuel fill hose from the fuel tank.
  7. Clean all the fuel pipe connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
  8. Disconnect the rear fuel return pipe at the chassis fuel return pipe. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-186616-S14431155502005083000000) .
  9. Disconnect the chassis fuel feed pipe at the fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-186616-S14431155502005083000000) .
  10. Disconnect the chassis evaporative emission (EVAP) purge pipe at the EVAP canister.
  11. Cap the fuel and EVAP pipes in order to prevent fuel system contamination.
  12. With the aid of an assistant, support the fuel tank.
  13. Remove the attaching bolts (4) from the fuel tank strap.
  14. Remove the fuel tank straps (3).
  15. Carefully lower the fuel tank.
  16. Disconnect the fuel sender and the fuel pressure sensor electrical connectors.
  17. Remove the fuel tank.
  18. Place the fuel tank in a suitable work area.
  19. Disconnect the EVAP pipe at the front roll-over valve (5), the rear roll-over valve (2), the EVAP canister (4), and the retainer clips.
  20. Remove the fuel sender assembly and the fuel pipes (6) from the fuel tank and the fuel filter. Refer to «Fuel Sender Assembly Replacement»(ref-186616-S31826379002005083000000) .
  21. Remove the fuel fill hose from the fuel tank.
  22. Remove the fuel tank from the fuel tank shield.
  1. Install the fuel tank insulators (3).
  2. Install the fuel tank into the fuel tank shield.
  3. Install the fuel fill hose to the fuel tank. Tighten: Tighten the fuel fill hose clamp to 2.75 N.m (24 lb in).
  4. Install the fuel sender assembly and the fuel pipes (6) to the fuel tank and the fuel filter. Refer to «Fuel Sender Assembly Replacement»(ref-186616-S31826379002005083000000) .
  5. Connect the EVAP pipe at the front roll-over valve (5), the rear roll-over valve (2), the EVAP canister (4), and the retainer clips.
  6. With the aid of an assistant, position and support the fuel tank.
  7. Raise the fuel tank slightly.
  8. Connect the electrical connectors to the fuel sender and the fuel pressure sensor.
  9. Raise the tank fully.
  10. Install the fuel tank straps (3).
  11. Install the new attaching bolts (4) to the fuel tank strap. Tighten: Tighten the bolts to 20.5 N.m (15 lb ft).
  12. Remove the caps from the fuel and EVAP pipes.
  13. Connect the chassis EVAP purge pipe to the EVAP canister.
  14. Connect the chassis fuel feed pipe to the fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-186616-S14431155502005083000000) .
  15. Connect the rear fuel return pipe to the chassis fuel return pipe. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-186616-S14431155502005083000000) .
  16. Connect the fuel fill hose to the fuel fill pipe. Tighten: Tighten the fuel fill hose clamp to 2.75 N.m (24 lb in).
  17. Lower the vehicle.
  18. Refill the fuel tank.
  19. Tighten the fuel filler cap.
  20. Connect the negative battery cable.
  21. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-186616-S33408734262005083000000) .
  3. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-186616-S26971635402005083000000) .
  4. Raise the vehicle. This must be done with a frame hoist in order to allow the rear suspension to hang. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  5. Loosen the fuel fill hose clamp (2).
  6. Disconnect the fuel fill hose from the fuel tank (1).
  7. Clean all the fuel pipe connections and the surrounding areas before disconnecting the fuel pipes in order to avoid contamination of the fuel system.
  8. Disconnect the rear fuel and evaporative emissions (EVAP) pipes (2) at the chassis fuel and EVAP pipes. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-186616-S14431155502005083000000) .
  9. Cap the fuel and EVAP pipes in order to prevent fuel system contamination.
  10. With the aid of an assistant, support the fuel tank.
  11. Remove the attaching bolts (4) from the fuel tank strap.
  12. Remove the fuel tank straps (3).
  13. Carefully lower the fuel tank.
  14. Disconnect the electrical connectors from the fuel sender and the fuel pressure sensor.
  15. Remove the fuel tank.
  16. Place the fuel tank in a suitable work area.
  17. Remove the fuel sender assembly and the rear fuel and EVAP pipes from the fuel tank. Refer to «Fuel Sender Assembly Replacement»(ref-186616-S31826379002005083000000) .
  1. Install the fuel tank insulators.
  2. Install the fuel sender assembly and the rear fuel and EVAP pipes to the fuel tank. Refer to «Fuel Sender Assembly Replacement»(ref-186616-S31826379002005083000000) .
  3. With the aid of an assistant, position and support the fuel tank.
  4. Raise the fuel tank slightly.
  5. Connect the electrical connectors to the fuel sender and the fuel pressure sensor.
  6. Raise the tank fully.
  7. Install the fuel tank straps (3).
  8. Install the new attaching bolts (4) to the fuel tank strap. Tighten: Tighten the bolts to 20.5 N.m (15 lb ft).
  9. Remove the caps from the fuel and EVAP pipes.
  10. Connect the rear fuel and EVAP pipes (2) to the chassis fuel and EVAP pipes. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-186616-S14431155502005083000000) .
  11. Connect the fuel fill hose to the fuel tank (1). Tighten: Tighten the fuel fill hose clamp (2) to 2.75 N.m (24 lb in).
  12. Lower the vehicle.
  13. Refill the fuel tank.
  14. Tighten the fuel filler cap.
  15. Connect the negative battery cable.
  16. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  1. Disconnect the negative battery cable.
  2. Relieve the fuel pressure. Refer to «Fuel Pressure Relief Procedure»(ref-186616-S33408734262005083000000) .
  3. Raise the vehicle.
  4. Remove the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Side Tank)»(ref-186616-S25811533102005083000000) «Fuel Tank Replacement (Passenger/Cargo Van)»(ref-186616-S16667756582005083000000) «Fuel Tank Replacement (Cutaway Van Rear Tank)»(ref-186616-S37019160122005083000000) .
  5. Remove the fuel pressure sensor (1).
  1. Install the fuel pressure sensor (1).
  2. Install the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Side Tank)»(ref-186616-S25811533102005083000000) «Fuel Tank Replacement (Passenger/Cargo Van)»(ref-186616-S16667756582005083000000) «Fuel Tank Replacement (Cutaway Van Rear Tank)»(ref-186616-S37019160122005083000000) .
  3. Refill the fuel tank.
  4. Install the fuel filler cap.
  5. Connect the negative battery cable.
  6. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-186616-S33408734262005083000000) .
  3. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-186616-S26971635402005083000000) .
  4. Remove the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Side Tank)»(ref-186616-S25811533102005083000000) «Fuel Tank Replacement (Passenger/Cargo Van)»(ref-186616-S16667756582005083000000) «Fuel Tank Replacement (Cutaway Van Rear Tank)»(ref-186616-S37019160122005083000000) .
  5. Remove the fuel sender assembly. Refer to «Fuel Sender Assembly Replacement»(ref-186616-S31826379002005083000000) .
  6. Disconnect the fuel pump electrical connector (5).
  7. Remove the electrical connector retaining clip (6) from the fuel level sensor.
  8. Disconnect the electrical connector (7) from the fuel level sensor under the fuel sender cover.
  9. Remove the retaining clip (4) from the fuel level sensor.
  10. Squeeze the locking tangs and remove the fuel level sensor (3).
  1. Install the fuel level sensor (3).
  2. Install the retaining clip (4) to the fuel level sensor.
  3. Connect the electrical connector (7) to the fuel level sensor.
  4. Connect the electrical connector retaining clip (6) to the fuel level sensor.
  5. Connect the fuel pump electrical connector (5).
  6. Install the fuel sender assembly. Refer to «Fuel Sender Assembly Replacement»(ref-186616-S31826379002005083000000) .
  7. Install the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Side Tank)»(ref-186616-S25811533102005083000000) or «Fuel Tank Replacement (Passenger/Cargo Van)»(ref-186616-S16667756582005083000000) or «Fuel Tank Replacement (Cutaway Van Rear Tank)»(ref-186616-S37019160122005083000000) .
  8. Refill the fuel tank.
  9. Install the fuel filler cap.
  10. Connect the negative battery cable.
  11. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.

Fuel Strainer Replacement

Tools Required

  1. J 34730-1A Fuel Pressure Gage. See «Special Tools & Equipment»(ref-186616-S38154004832005083000000) .
  2. J 39765 Fuel Sender Lock Nut Wrench. See «Special Tools & Equipment»(ref-186616-S38154004832005083000000) .
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-186616-S33408734262005083000000) .
  3. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-186616-S26971635402005083000000) .
  4. Remove the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Side Tank)»(ref-186616-S25811533102005083000000) or «Fuel Tank Replacement (Passenger/Cargo Van)»(ref-186616-S16667756582005083000000) or «Fuel Tank Replacement (Cutaway Van Rear Tank)»(ref-186616-S37019160122005083000000) .
  5. Remove the fuel sender assembly. Refer to «Fuel Sender Assembly Replacement»(ref-186616-S31826379002005083000000) .
  6. Note the position of the fuel strainer (2) on the fuel sender.
  7. Support the fuel sender assembly with one hand and grasp the strainer with the other hand.
  8. Pull the strainer off the fuel sender. Discard the strainer after inspection.
  9. Inspect the strainer. Replace a contaminated strainer and clean the fuel tank.
  1. Install a new fuel strainer (2) in the same position as noted during disassembly. Push the strainer on the bottom of the fuel sender until the strainer is fully seated.
  2. Install the fuel sender assembly. Refer to «Fuel Sender Assembly Replacement»(ref-186616-S31826379002005083000000) .
  3. Install the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Side Tank)»(ref-186616-S25811533102005083000000) or «Fuel Tank Replacement (Passenger/Cargo Van)»(ref-186616-S16667756582005083000000) or «Fuel Tank Replacement (Cutaway Van Rear Tank)»(ref-186616-S37019160122005083000000) .
  4. Refill the fuel tank.
  5. Install the fuel filler cap.
  6. Connect the negative battery cable.
  7. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-186616-S33408734262005083000000) .
  3. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-186616-S26971635402005083000000) .
  4. Remove the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Side Tank)»(ref-186616-S25811533102005083000000) or «Fuel Tank Replacement (Passenger/Cargo Van)»(ref-186616-S16667756582005083000000) or «Fuel Tank Replacement (Cutaway Van Rear Tank)»(ref-186616-S37019160122005083000000) .
  5. Remove the fuel sender assembly. Refer to «Fuel Sender Assembly Replacement»(ref-186616-S31826379002005083000000) .
  6. Note the position of the fuel strainer (2) on the fuel sender.
  7. Support the fuel sender assembly with one hand and grasp the strainer with the other hand.
  8. Pull the strainer off the fuel sender. Discard the strainer after inspection.
  9. Inspect the strainer. Replace a contaminated strainer and clean the fuel tank.
  10. Disconnect the fuel pump electrical connector (5).
  11. Remove the electrical connector retaining clip (6) from the fuel level sensor.
  12. Disconnect the electrical connector (7) from the fuel level sensor under the fuel sender cover.
  13. Remove the retaining clip (4) from the fuel level sensor.
  14. Squeeze the locking tangs and remove the fuel level sensor (3).
  15. Remove the fuel pressure sensor (1).
  1. Install the fuel pressure sensor (1).
  2. Install the fuel level sensor (3).
  3. Install the retaining clip (4) to the fuel level sensor.
  4. Connect the electrical connector (7) to the fuel level sensor.
  5. Connect the electrical connector retaining clip (6).
  6. Connect the fuel pump electrical connector (5). IMPORTANT: Always install a new fuel strainer when replacing the fuel tank fuel pump module.
  7. Install a new fuel strainer (2) in the same position as noted during disassembly. Push the strainer on the bottom of the fuel sender until the strainer is fully seated.
  8. Install the fuel sender assembly. Refer to «Fuel Sender Assembly Replacement»(ref-186616-S31826379002005083000000) .
  9. Install the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Side Tank)»(ref-186616-S25811533102005083000000) or «Fuel Tank Replacement (Passenger/Cargo Van)»(ref-186616-S16667756582005083000000) or «Fuel Tank Replacement (Cutaway Van Rear Tank)»(ref-186616-S37019160122005083000000) .
  10. Refill the fuel tank.
  11. Tighten the fuel filler cap.
  12. Connect the negative battery cable.
  13. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  1. Clean all the fuel pipe and hose connections and the surrounding areas before disconnecting in order to avoid contamination of the fuel system.
  2. Remove the fuel filler cap.
  3. Drain the fuel below the level of the fuel tank fill hose. Refer to «Fuel Tank Draining Procedure»(ref-186616-S26971635402005083000000) .
  4. Remove the 2 retaining bolts and push-pin that retain the filler neck to the body.
  5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  6. Remove the fuel filler tube ground strap bolt.
  7. Loosen the fuel fill hose to fuel fill pipe clamp.
  8. Disconnect the fuel fill hose from the fuel fill pipe.
  9. Remove the fuel fill pipe assembly.
  1. Install the fuel fill pipe to the fuel fill hose.
  2. Align the fuel fill pipe to the fuel fill pipe housing. Tighten: Tighten the fuel fill hose clamp to 2.75 N.m (24 lb in).
  3. Install the fuel filler tube ground strap bolt. Tighten: Tighten the fuel filler tube ground strap bolt to 8 N.m (70 lb in).
  4. Lower the vehicle.
  5. Install the fuel fill pipe housing bolts and push-pin. Tighten: Tighten the fuel fill pipe housing bolts to 6 N.m (53 lb in).
  6. Refill the fuel tank.
  7. Install the fuel filler cap.
  1. Clean all the fuel pipe and hose connections and the surrounding areas before disconnecting in order to avoid contamination of the fuel system.
  2. Remove the fuel filler cap.
  3. Drain the fuel below the level of the fuel tank fill hose. Refer to «Fuel Tank Draining Procedure»(ref-186616-S26971635402005083000000) .
  4. Remove the 2 retaining bolts and push-pin that retain the filler neck to the body.
  5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  6. Remove the fuel filler tube ground strap bolt.
  7. Loosen the fuel fill hose to fuel fill pipe clamp.
  8. Disconnect the fuel fill hose from the fuel fill pipe.
  9. Remove the fuel fill pipe assembly.
  1. Install the fuel fill pipe to the fuel fill hose.
  2. Align the fuel fill pipe to the fuel fill pipe housing. Tighten: Tighten the fuel fill hose clamp to 2.75 N.m (24 lb in).
  3. Install the fuel filler tube ground strap bolt. Tighten: Tighten the fuel filler tube ground strap bolt to 8 N.m (70 lb in).
  4. Lower the vehicle.
  5. Install the fuel fill pipe housing bolts and push-pin. Tighten: Tighten the fuel fill pipe housing bolts to 6 N.m (53 lb in).
  6. Refill the fuel tank.
  7. Install the fuel filler cap.
  1. Clean all the fuel pipe and hose connections and the surrounding areas before disconnecting in order to avoid contamination of the fuel system.
  2. Remove the fuel filler cap.
  3. Drain the fuel below the level of the fuel tank fill hose. Refer to «Fuel Tank Draining Procedure»(ref-186616-S26971635402005083000000) .
  4. Remove the 2 retaining bolts and push-pin that retain the filler neck to the body.
  5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  6. Remove the fuel filler tube ground strap bolt.
  7. Loosen the fuel fill hose to fuel fill pipe clamp.
  8. Disconnect the fuel fill hose from the fuel fill pipe.
  9. Remove the fuel fill pipe assembly.
  1. Install the fuel fill pipe to the fuel fill hose.
  2. Align the fuel fill pipe to the fuel fill pipe housing. Tighten: Tighten the fuel fill hose clamp to 2.75 N.m (24 lb in).
  3. Install the fuel filler tube ground strap bolt. Tighten: Tighten the fuel filler tube ground strap bolt to 8 N.m (70 lb in).
  4. Lower the vehicle.
  5. Install the fuel fill pipe housing bolts and push-pin. Tighten: Tighten the fuel fill pipe housing bolts to 6 N.m (53 lb in).
  6. Refill the fuel tank.
  7. Install the fuel filler cap.
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-186616-S33408734262005083000000) .
  3. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-186616-S26971635402005083000000) .
  4. Remove the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Side Tank)»(ref-186616-S25811533102005083000000) or «Fuel Tank Replacement (Passenger/Cargo Van)»(ref-186616-S16667756582005083000000) or «Fuel Tank Replacement (Cutaway Van Rear Tank)»(ref-186616-S37019160122005083000000) .
  5. Remove the retaining ring from the fuel sender assembly using the J 39765 . See «Special Tools & Equipment»(ref-186616-S38154004832005083000000) .
  6. Remove the fuel sender assembly and the seal. Discard the seal.
  7. 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.
  3. Install the retaining ring to the fuel sender assembly using the J 39765 . See «Special Tools & Equipment»(ref-186616-S38154004832005083000000) .
  4. Install the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Side Tank)»(ref-186616-S25811533102005083000000) or «Fuel Tank Replacement (Passenger/Cargo Van)»(ref-186616-S16667756582005083000000) or «Fuel Tank Replacement (Cutaway Van Rear Tank)»(ref-186616-S37019160122005083000000) .
  5. Refill the fuel tank.
  6. Tighten the fuel filler cap.
  7. Connect the negative battery cable.
  8. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-186616-S33408734262005083000000) .
  3. Disconnect the fuel feed and return pipes (3) from the engine compartment fuel pipes (4).
  4. Remove the fuel pipes from the bellhousing stud retainer clip (2).
  5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  6. Disconnect the fuel feed pipe (5) at the fuel filter.
  7. Disconnect the chassis fuel return pipe (4) at the rear fuel return pipe (3).
  8. Remove the fuel pipe retaining clips (1). Note the location of the retaining clips for installation.
  9. Remove the fuel feed and return pipes (2).
  1. Position the fuel feed and return pipes (2) in the vehicle.
  2. Install the fuel pipe retaining clips (1). Tighten: Tighten the bolts to 12 N.m (106 lb in).
  3. Connect the chassis fuel return pipe (4) to the rear fuel return pipe (3).
  4. Connect the fuel feed pipe (5) to the fuel filter.
  5. Lower the vehicle.
  6. Connect the fuel feed and return pipes (3) to the engine compartment fuel pipes (4). Ensure the O-rings are in place Tighten: Tighten the fuel pipe fittings to 27 N.m (20 lb ft) using a backup wrench.
  7. Install the fuel pipes to the retainer clip (2). Tighten: Tighten the fuel pipe retainer clip nut to 28 N.m (21 lb ft).
  8. Tighten the fuel filler cap.
  9. Connect the negative battery cable.
  10. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  11. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-186616-S33408734262005083000000) .
  3. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-186616-S26971635402005083000000) .
  4. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  5. Disconnect the fuel feed pipe the fuel filter.
  6. Disconnect the chassis fuel return pipe the rear fuel return pipe.
  7. Disconnect the chassis fuel feed and return pipes at the rear fuel feed and return pipes (2).
  8. Remove the fuel pipe retaining clips (1).
  9. Remove the fuel feed and return pipes.
  1. Install the fuel feed and return pipes and the fuel pipe retaining clips (1) to the frame rail. Tighten: Tighten the bolts to 12 N.m (106 lb in).
  2. Connect the chassis fuel feed and return pipes to the rear fuel feed and return pipes (2).
  3. Connect the chassis fuel return pipe to the rear fuel return pipe (2).
  4. Connect the fuel feed pipe to the fuel filter.
  5. Lower the vehicle.
  6. Refill the fuel tank.
  7. Tighten the fuel filler cap.
  8. Connect the negative battery cable.
  9. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  10. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-186616-S33408734262005083000000) .
  3. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-186616-S26971635402005083000000) .
  4. Remove the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Side Tank)»(ref-186616-S25811533102005083000000) or «Fuel Tank Replacement (Passenger/Cargo Van)»(ref-186616-S16667756582005083000000) or «Fuel Tank Replacement (Cutaway Van Rear Tank)»(ref-186616-S37019160122005083000000) .
  5. Disconnect the fuel feed pipe at the fuel filter.
  6. Disconnect the chassis fuel return pipe (4) at the rear fuel return pipe (2).
  7. Remove the fuel pipe retaining clips (1).
  8. Remove the fuel feed and return pipes.
  1. Install the fuel feed and return pipes and the fuel pipe retaining clips (1). Tighten: Tighten the bolts to 12 N.m (106 lb in).
  2. Connect the chassis fuel return pipe to the rear fuel return pipe.
  3. Connect the fuel feed pipe to the fuel filter.
  4. Install the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Side Tank)»(ref-186616-S25811533102005083000000) or «Fuel Tank Replacement (Passenger/Cargo Van)»(ref-186616-S16667756582005083000000) or «Fuel Tank Replacement (Cutaway Van Rear Tank)»(ref-186616-S37019160122005083000000) .
  5. Lower the vehicle.
  6. Refill the fuel tank.
  7. Tighten the fuel filler cap.
  8. Connect the negative battery cable.
  9. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  10. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-186616-S33408734262005083000000) .
  3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-186616-S40473932682005083000000) .
  4. Loosen the fuel and evaporative emissions (EVAP) pipe retainer (2) nut at the bellhousing stud.
  5. Disconnect the chassis fuel feed and return pipes (3) at the engine compartment fuel feed and return pipes (4).
  6. Remove the injector fuel inlet and outlet pipe retainer nuts.
  7. Remove the injector fuel inlet and the outlet pipe retainer.
  8. Remove the retaining bolt from the rear fuel pipe bracket.
  9. Pull straight up on the fuel pipes in order to remove the fuel pipes from the injector assembly.
  10. Remove the O-ring seals from both ends of the fuel feed and return pipes.
  11. Discard the O-ring seals.
  1. Assemble the new O-rings into the inlet and outlet of the fuel injector assembly.
  2. Apply a few drops of clean engine oil to the male tube ends.
  3. Install the fuel feed and return pipes to the injector assembly.
  4. Install the fuel pipe retainer and the attaching nuts.
  5. Install the retaining bolt to the rear fuel pipe bracket. Tighten: Tighten the bracket bolt to 6 N.m (53 lb in). Tighten the retainer nuts to 3 N.m (27 lb in).
  6. Install the new O-ring seals on the engine fuel feed and the return pipes.
  7. Install the chassis fuel feed and return pipes (3) to the engine compartment fuel feed and return pipes (4). Tighten: Tighten the fuel pipe nuts to 27 N.m (20 lb ft).
  8. Install the retainer nut to the fuel and EVAP pipe. Tighten: Tighten the retainer nut to 28 N.m (21 lb ft).
  9. Tighten the fuel filler cap.
  10. Connect the negative battery cable.
  11. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  12. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-186616-S40473932682005083000000) .
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-186616-S33408734262005083000000) .
  3. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-186616-S26971635402005083000000) .
  4. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  5. Disconnect the fuel feed pipe at the fuel filter.
  6. Disconnect the chassis fuel return pipe at the rear fuel return pipe.
  7. Disconnect the chassis fuel feed and return pipes at the rear fuel feed and return pipes.
  8. Remove the fuel pipe retaining clips.
  9. Remove the fuel feed and return pipes.
  1. Install the fuel feed and return pipes and the fuel pipe retaining clips (2) to the frame rail (1). Tighten: Tighten the bolts to 12 N.m (106 lb in).
  2. Connect the chassis fuel feed and return pipes to the rear fuel feed and return pipes (2).
  3. Connect the chassis fuel return pipe to the rear fuel return pipe.
  4. Connect the fuel feed pipe to the fuel filter.
  5. Lower the vehicle.
  6. Refill the fuel tank.
  7. Tighten the fuel filler cap.
  8. Connect the negative battery cable.
  9. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition switch. Inspect for fuel leaks.
  10. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-186616-S33408734262005083000000) .
  3. Disconnect the fuel feed and return pipes (3) from the engine compartment fuel pipes (4).
  4. Remove the fuel pipes from the bellhousing stud retainer clip.
  5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  6. Disconnect the fuel feed pipe at the fuel filter.
  7. Disconnect the chassis fuel return pipe at the rear fuel return pipe.
  8. Remove the fuel pipe retaining clips. Note the location of the retaining clips for installation.
  9. Remove the fuel feed and return pipes.
  1. Position the fuel feed and return pipes in the vehicle.
  2. Install the fuel pipe retaining clips (1). Tighten: Tighten the clips to 12 N.m (106 lb in).
  3. Connect the chassis fuel return pipe (4) to the rear fuel return pipe.
  4. Connect the fuel feed pipe (5) to the fuel filter.
  5. Lower the vehicle.
  6. Install the fuel feed and return pipes to the engine compartment fuel pipes. Tighten: Tighten the fuel pipe fittings to 27 N.m (20 lb ft).
  7. Install the fuel pipes to the retainer clip. Tighten: Tighten the fuel pipe retainer clip nut to 28 N.m (21 lb ft).
  8. Tighten the fuel filler cap.
  9. Connect the negative battery cable.
  10. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  11. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-186616-S33408734262005083000000) .
  3. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-186616-S26971635402005083000000) .
  4. Remove the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Side Tank)»(ref-186616-S25811533102005083000000) or «Fuel Tank Replacement (Passenger/Cargo Van)»(ref-186616-S16667756582005083000000) or «Fuel Tank Replacement (Cutaway Van Rear Tank)»(ref-186616-S37019160122005083000000) .
  5. Disconnect the fuel feed pipe at the fuel filter.
  6. Disconnect the chassis fuel return pipe at the rear fuel return pipe.
  7. Remove the fuel pipe retaining clips.
  8. Remove the fuel feed and return pipes.
  1. Install the fuel feed and return pipes and the fuel pipe retaining clips (1). Tighten: Tighten the bolts to 12 N.m (106 lb in).
  2. Connect the chassis fuel return pipe to the rear fuel return pipe.
  3. Connect the fuel feed pipe to the fuel filter.
  4. Install the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Side Tank)»(ref-186616-S25811533102005083000000) or «Fuel Tank Replacement (Passenger/Cargo Van)»(ref-186616-S16667756582005083000000) or «Fuel Tank Replacement (Cutaway Van Rear Tank)»(ref-186616-S37019160122005083000000) .
  5. Lower the vehicle.
  6. Refill the fuel tank.
  7. Tighten the fuel filler cap.
  8. Connect the negative battery cable.
  9. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  10. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-186616-S33408734262005083000000) .
  3. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-186616-S26971635402005083000000) .
  4. Remove the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Side Tank)»(ref-186616-S25811533102005083000000) or «Fuel Tank Replacement (Passenger/Cargo Van)»(ref-186616-S16667756582005083000000) or «Fuel Tank Replacement (Cutaway Van Rear Tank)»(ref-186616-S37019160122005083000000) .
  5. Remove the fuel feed and return pipes (6) from the fuel sender (1), the fuel filter, and the retaining clips.
  1. Install the fuel feed and return pipes (6) to the fuel sender (1), the fuel filter, and the retaining clips.
  2. Install the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Side Tank)»(ref-186616-S25811533102005083000000) or «Fuel Tank Replacement (Passenger/Cargo Van)»(ref-186616-S16667756582005083000000) or «Fuel Tank Replacement (Cutaway Van Rear Tank)»(ref-186616-S37019160122005083000000) .
  3. Lower the vehicle.
  4. Refill the fuel tank.
  5. Tighten the fuel filler cap.
  6. Connect the negative battery cable.
  7. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-186616-S33408734262005083000000) .
  3. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-186616-S26971635402005083000000) .
  4. Remove the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Side Tank)»(ref-186616-S25811533102005083000000) or «Fuel Tank Replacement (Passenger/Cargo Van)»(ref-186616-S16667756582005083000000) or «Fuel Tank Replacement (Cutaway Van Rear Tank)»(ref-186616-S37019160122005083000000) .
  5. Remove the fuel feed and return pipes (4) from the fuel sender (2).
  1. Install the fuel feed and return pipes (4) to the fuel sender (2).
  2. Install the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Side Tank)»(ref-186616-S25811533102005083000000) or «Fuel Tank Replacement (Passenger/Cargo Van)»(ref-186616-S16667756582005083000000) or «Fuel Tank Replacement (Cutaway Van Rear Tank)»(ref-186616-S37019160122005083000000) .
  3. Lower the vehicle.
  4. Refill the fuel tank.
  5. Tighten the fuel filler cap.
  6. Connect the negative battery cable.
  7. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) Interior Trim.
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-186616-S33408734262005083000000) .
  3. Use a standard valve core tool in order to remove the valve core (2).
  1. Use a standard valve core tool in order to install a new valve core (2).
  2. Tighten the fuel filler cap.
  3. Connect the negative battery cable.
  4. Inspect for leaks. Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition for 2 seconds. Inspect for fuel leaks.
  5. Install the fuel pressure connection valve cap (3).
  6. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) Interior Trim.
IMPORTANTAn 8-digit part identification number is on a mylar label affixed to the fuel meter body. Refer to this number if servicing or part replacement is required.
  1. Remove the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(ref-186638-S15188406172005083000000) in Engine Mechanical - 4.3L.
  2. Remove and discard the fuel meter body seal.
  3. Before removal, clean the fuel meter body with a spray type engine cleaner, such as GM X-30A, or equivalent, if necessary. Follow the package instructions. Do not soak the fuel meter body in liquid cleaning solvent.
  4. Remove the injectors from the lower intake manifold bores. Lightly pull on the injector tube and using a small pocket screwdriver, remove the injector from the manifold.
  5. Remove the MFI (multi-port flexible injection) fuel meter body from the MFI bracket.
IMPORTANTThe number 3 fuel tube must be positioned behind the number 1 fuel tube to eliminate interference with the upper intake manifold when installed.
  1. Position the fuel tubes of the MFI fuel meter body in the forward position.
  2. Install the MFI fuel meter body into the fuel meter body bracket on the lower intake manifold. Push down firmly to lock the fuel meter body into the fuel meter body bracket.
  3. Insert the injectors in the following sequence into the correct injector bore in the lower manifold. Number 3 Number 5 Number 1 Number 2 Number 4 Number 6
  4. Insure the electrical connectors on the injectors are positioned so that they do not interfere with each other and are pointing towards the center of the intake manifold. Rotate the electrical connectors inboard if necessary.
  5. Lubricate the upper intake manifold O-ring on the fuel meter body with clean engine oil.
  6. Install the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(ref-186638-S15188406172005083000000) in Engine Mechanical - 4.3L.
  7. Tighten the fuel fill cap.
  8. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-186595-S11053284922005083000000) in Engine Electrical.
  9. Test for fuel leaks using the following procedure: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
  1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) Interior Trim.
  2. Remove the upper intake manifold assembly. Refer to «Intake Manifold Replacement - Upper»(ref-186638-S15188406172005083000000) in Engine Mechanical - 4.3L.
  3. Remove the fuel pressure regulator retainer clip (13).
  4. Pull and twist the fuel pressure regulator (14) in order to remove the fuel pressure regulator from the fuel pressure regulator housing using a shop towel to catch any spilled fuel.
  5. Remove the regulator seal lower O-ring (18).
  6. Remove the regulator assembly filter (17).
  7. Remove the regulator seal upper O-ring (16).
  8. Remove the regulator seal backup ring (15).
  9. Cover the fuel pressure regulator housing to prevent contamination from entering the fuel system.
  10. Discard the O-rings.
IMPORTANTIf the fuel pressure regulator is to be reinstalled, inspect the filter screen for contamination. If the filter screen is contaminated, replace the regulator.
  1. Lubricate the new O-rings with clean engine oil.
  2. Install the regulator seal backup ring (15).
  3. Install the regulator seal upper O-ring (16).
  4. Install the regulator assembly filter (17).
  5. Install the regulator seal lower O-ring (18).
  6. Assemble the regulator with the vacuum tube pointing down into the regulator retainer clip.
  7. Install the fuel pressure regulator retainer clip (13).
  8. Install the upper manifold assembly. Refer to «Intake Manifold Replacement - Upper»(ref-186638-S15188406172005083000000) in Engine Mechanical-4.3L.
  9. Tighten the fuel filler cap.
  10. Connect the negative battery cable.
  11. Inspect for leaks. Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  12. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  1. Remove the fuel meter body assembly. Refer to «Fuel Meter Body Assembly Replacement»(ref-186616-S33354935262005083000000) .
  2. Remove the injector assembly retainer (11) and the injector retainer lock nuts (10).
  3. While pulling the poppet nozzle tube downward, push with a small tip punch down between the injector terminals until the injector is removed.
IMPORTANTEach injector is calibrated for a specific flow rate. Order the correct injector for the application being serviced when replacing the fuel injectors.
  1. Lubricate the new injector O-ring seals with clean engine oil.
  2. Install the O-rings on the injector assembly (2).
  3. Install the fuel injector assembly (12) into the injector socket.
  4. Install the injector assembly retainer (11) and the injector retainer lock nuts (10). Tighten: Tighten the lock nuts to 3.0 N.m (27 lb in).
  5. Install the fuel meter body assembly. Refer to «Fuel Meter Body Assembly Replacement»(ref-186616-S33354935262005083000000) .
  1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  2. Disconnect the
  3. Disconnect the purge valve electrical connector.
  4. Remove the purge valve mounting nuts.
  5. Remove the engine wiring harness bracket from the mounting stud.
  6. Remove the purge valve from the intake manifold.
  1. Install the purge valve to the intake manifold.
  2. Install the engine wiring harness bracket to the mounting stud.
  3. Install the purge valve mounting nuts. Tighten: Tighten the nuts to 12 N.m (106 lb in).
  4. Connect the purge valve electrical connector.
  5. Connect the EVAP purge pipe.
  6. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  2. Disconnect the electrical connector from the EVAP vent valve.
  3. Disconnect the canister vent hose.
  4. Bend back the tang on the bracket.
  5. Slide the EVAP vent valve off the bracket.
  1. Slide the EVAP vent valve onto the bracket.
  2. Connect the canister vent hose.
  3. Connect the electrical connector to the EVAP vent valve.
  4. Lower the vehicle.
IMPORTANTWhen replacing the evaporative emission (EVAP) pipe, always replace the pipe with original equipment or parts that meet the GM specifications for this part. The replacement pipe must have the same type of fittings as the original pipe in order to ensure the integrity of the connection.
  1. Clean the pipe connections and the surrounding areas before disconnecting in order to avoid possible contamination of the EVAP system.
  2. Disconnect the engine compartment EVAP pipe at the EVAP canister purge valve.
  3. Disconnect the engine compartment EVAP pipe (1) at the chassis EVAP pipe (2).
  4. Remove the EVAP pipe from the engine.
  5. Cap the EVAP canister purge valve and the chassis EVAP pipe in order to prevent possible EVAP system contamination.
  1. Remove the caps from the EVAP canister purge valve and the chassis EVAP pipe.
  2. Install the EVAP pipe on the engine.
  3. Connect the engine compartment EVAP pipe (1) to the chassis EVAP pipe (2).
  4. Connect the engine compartment EVAP pipe at the EVAP canister purge valve.
IMPORTANTWhen replacing the evaporative emission (EVAP) pipe, always replace the pipe with original equipment or parts that meet the GM specifications for this part. The replacement pipe must have the same type of fittings as the original pipe in order to ensure the integrity of the connection.
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Side Tank)»(ref-186616-S25811533102005083000000) or «Fuel Tank Replacement (Passenger/Cargo Van)»(ref-186616-S16667756582005083000000) or «Fuel Tank Replacement (Cutaway Van Rear Tank)»(ref-186616-S37019160122005083000000) .
  2. Disconnect the rear EVAP vapor pipe (1) from the fuel sender (2), the fuel tank roll over valve (3), and the fuel tank clips (6).
  3. Remove the EVAP vapor pipe from the fuel tank.
  4. Cap the fuel sender EVAP pipe and the fuel tank roll over valve.
  1. Remove the caps from the fuel sender EVAP pipe and the fuel tank roll over valve.
  2. Position the EVAP vapor pipe on the fuel tank.
  3. Connect the EVAP vapor pipe (1) to the fuel sender (2), the fuel tank roll over valve (3), and the fuel tank clips (6).
  4. Install the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Side Tank)»(ref-186616-S25811533102005083000000) or «Fuel Tank Replacement (Passenger/Cargo Van)»(ref-186616-S16667756582005083000000) or «Fuel Tank Replacement (Cutaway Van Rear Tank)»(ref-186616-S37019160122005083000000) .
IMPORTANTWhen replacing the evaporative emission (EVAP) pipe, always replace the pipe with original equipment or parts that meet the GM specifications for this part. The replacement pipe must have the same type of fittings as the original pipe in order to ensure the integrity of the connection.
  1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  2. Clean all the EVAP pipe connections and the surrounding areas before disconnecting the pipes in order to avoid possible contamination of the EVAP system.
  3. Disconnect the engine compartment EVAP pipe (1) from the chassis EVAP pipe (2).
  4. Cap the engine compartment EVAP pipe.
  5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  6. Remove the EVAP pipe from the bellhousing stud clip.
  7. Remove the EVAP pipe from the transmission bracket clip.
  8. Remove the EVAP pipe from the transfer case bracket clip, AWD drive only.
  9. Disconnect the rear EVAP purge pipe (3) from the chassis EVAP purge pipe (2).
  10. Cap the rear EVAP purge pipe (3).
  11. Note the position of the EVAP pipe for aid in installation.
  12. Remove the EVAP pipe from the retaining clips (1).
  13. Remove the EVAP pipe.
  1. Install the EVAP pipe into the retaining clips (1).
  2. Remove the cap from the rear EVAP pipe.
  3. Connect the rear EVAP purge pipe (3) to the chassis EVAP purge pipe (2).
  4. Install the EVAP pipe into the transfer case bracket clip, AWD drive only.
  5. Install the EVAP pipe into the transmission bracket clip.
  6. Install the EVAP pipe into the bellhousing stud clip (3).
  7. Lower the vehicle.
  8. Remove the cap from the engine compartment EVAP pipe.
  9. Connect the engine compartment EVAP pipe (1) to the chassis EVAP pipe (2).
  10. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  2. Disconnect the vent hose from the canister.
  3. Disconnect the chassis EVAP purge pipe from the EVAP canister.
  4. Disconnect the fuel tank EVAP pipe from the canister.
  5. Remove the EVAP canister from the EVAP canister bracket.
  1. Install the EVAP canister to the EVAP canister bracket.
  2. Connect the fuel tank EVAP pipe to the canister.
  3. Connect the chassis EVAP purge pipe to the EVAP canister.
  4. Connect the vent hose to the canister.
  5. Lower the vehicle.
  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  2. Disconnect the vent hose from the canister.
  3. Disconnect the chassis EVAP purge pipe from the EVAP canister.
  4. Disconnect the fuel tank EVAP pipe from the canister.
  5. Remove the EVAP canister from the EVAP Canister bracket.
  1. Connect the fuel tank EVAP pipe to the canister.
  2. Connect the chassis EVAP purge pipe to the EVAP canister.
  3. Connect the vent hose to the canister.
  4. Install the EVAP canister to the EVAP Canister bracket.
  5. Install the EVAP canister bracket bolt. Tighten: Tighten the bolt to 12 N.m (106 lb in).
  6. Lower the vehicle.

Note. There are two procedures available to install the distributor. Use Installation Procedure 1 when the crankshaft has NOT been rotated from the original position. Use Installation Procedure 2 when any of the following components are removed. The intake manifold The cylinder head The camshaft The timing chain or sprockets The complete engine If the malfunction indicator lamp (MIL) turns on and DTC P1345 sets after installing the distributor, this indicates an incorrectly installed distributor. Engine damage or distributor damage may occur. Use Procedure 2 in order to install the distributor.

  1. Turn OFF the ignition.
  2. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  3. Remove air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186616-S30400857942005083000000) .
  4. Remove the air intake resonator assembly.
  5. Remove the spark plug wires from the distributor cap. Twist each spark plug wire boot 1/2 turn. Pull only on the wire boot in order to remove the wire from the distributor cap.
  6. Remove the electrical connector from the base of the distributor.
  7. Remove the 2 screws that retain the distributor cap to the housing.
  8. Discard the screws.
  9. Remove the distributor cap from the housing.
  10. Use a grease pencil in order to mark the position of the rotor in relation to the distributor housing (1).
  11. Mark the distributor housing and the intake manifold with the grease pencil.
  12. As the distributor is being removed from the engine, watch the rotor move in a counter-clockwise direction about 42 degrees. This will appear as slightly more than one clock position.
  13. Note the position of the rotor segment.
  14. Place a second mark on the base of the distributor (2). This will aid in achieving the proper rotor alignment during the distributor installation.
  15. Remove the mounting clamp hold-down bolt.
  16. Remove the distributor.

Installation Procedure 1

  1. If installing a new distributor assembly, place 2 marks on the new distributor housing in the same location as the marks on the original housing.
  2. Remove the new distributor cap, if necessary.
  3. Align the rotor with the second mark (2).
  4. Guide the distributor into the engine.
  5. Align the hole in the distributor hold-down base over the mounting hole in the intake manifold.
  6. As the distributor is being installed, observe the rotor moving in a clockwise direction about 42 degrees.
  7. Once the distributor is completely seated, the rotor segment should be aligned with the mark on the distributor base (1). If the rotor segment is not aligned with the mark, the driven gear teeth and the camshaft have meshed one or more teeth out of alignment. In order to correct this condition, remove and reinstall the distributor.
  8. Install the distributor mounting clamp bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  9. Install the distributor cap.
  10. Install the new distributor cap screws. Tighten: Tighten the screws to 2.4 N.m (21 lb in).
  11. Install the electrical connector to the distributor.
  12. Install the spark plug wires to the distributor cap.
  13. Install the ignition coil wire. Note the correct orientation of the wire boot.
  14. Refer to Installation Procedure 2 if the malfunction indicator lamp illuminates after installing the distributor.
  15. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.

Installation Procedure 2

  1. Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer are aligned with the tabs on the engine front cover and the number 1 piston is at TDC of the compression stroke.
  2. Align the white paint mark on the bottom stem of the distributor and the pre-drilled indent hole in the bottom of the gear (3).
  3. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1). The alignment will not be exact. If the driven gear is installed incorrectly, the dimple will be approximately 180 degrees opposite of the rotor segment when installed in the distributor.
  4. Use a long screw driver in order to align the oil pump drive shaft to the drive tab of the distributor.
  5. Guide the distributor into the engine. Ensure the flat portion of the distributor housing is facing toward the front of the engine.
  6. Once the distributor is fully seated, the rotor segment should be aligned with the pointer cast into the distributor base. If the rotor segment does not come within a few degrees of the pointer, repeat the procedure in order to achieve the proper alignment.
  7. Install the distributor mounting clamp bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  8. Install the distributor cap.
  9. Install the new distributor cap screws. Tighten: Tighten the screws to 2.4 N.m (21 lb in).
  10. Install the electrical connector to the distributor.
  11. Install the spark plug wires to the distributor cap.
  12. Install the ignition coil wire. Note the correct orientation of the wire boot.
  13. Repeat Installation Procedure 2 if the malfunction indicator lamp illuminates after installing the distributor.
  14. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  2. Disconnect the ignition coil electrical connectors.
  3. Remove the ignition coil wire to the distributor.
  4. Remove the accelerator cable bracket.
  5. Remove the studs holding the bracket and the ignition coil to the intake manifold.
  6. Remove the bracket and the ignition coil.
  7. Drill and punch out the two rivets holding the ignition coil to the bracket.
  8. Remove the ignition coil from the bracket.
  1. Install the ignition coil to the bracket with the 2 screws.
  2. Install the ignition coil and the bracket to the intake manifold with studs. Tighten: Tighten the studs to 11 N.m (97 lb in).
  3. Install the accelerator control bracket. Tighten: Tighten the accelerator control cable bracket nuts and studs to 12 N.m (106 lb in).
  4. Install the ignition coil wire. The wire must not touch anything like the dip stick. Rubbing will make a ground or short after time of use.
  5. Install the electrical connectors.
  6. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  2. Disconnect the electrical connector (3).
  3. Remove the screws (4) holding the ignition control module (2) and the heat sink (1) to the bracket.
  4. Remove the ignition control module and the heat sink.
  1. Install the ignition control module (2) and the heat sink (1) on the bracket with the screws (4). Tighten: Tighten the screws to 3.5 N.m (31 lb in).
  2. Reconnect the electrical connectors (3).
  3. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  2. Disconnect the spark plug wire at each spark plug. Twist the boots 1/2 turn before removing the boots. Pull only on the boot or use a tool designed for this purpose in order to remove the wire from each spark plug.
  3. Disconnect the spark plug wire from the distributor. Twist each spark plug boot 1/2 turn. Pull only on the boot or use a tool designed for this purpose in order to remove the wires from the distributor.
  1. Install the spark plug wires at the distributor.
  2. Install the spark plug wire to each spark plug.
  3. Inspect the wires for proper installation: Push sideways on each boot in order to inspect the seating. Reinstall any loose boot. Wire routings must be kept intact during service and followed exactly when wires have been disconnected or when replacement of the wires is necessary. Failure to route the wires properly can lead to radio ignition noise and crossfiring of the plugs, or shorting of the leads to the ground. Any time the spark plug wires or boots are installed on the spark plugs, new dielectric grease needs to be applied inside the boot.
  4. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  1. Remove the spark plug wires. Refer to «Spark Plug Wire Replacement»(ref-186616-S30604988412005083000000) .
  2. Loosen each spark plug 1 or 2 turns.
  3. Brush or air blast away any dirt from around the spark plugs.
  4. Remove the spark plugs 1 at a time. Place each plug in a tray marked with the corresponding cylinder numbers.
  1. Inspect each spark plug gap. Adjust each plug as needed. Specification: Spark plug gap: 1.524 mm (0.060 in).
  2. Hand start the spark plugs in the corresponding cylinders.
  3. Tighten the spark plugs. Tighten: For used heads, tighten the spark plugs to 15 N.m (11 lb ft). For new aluminum heads, tighten the spark plugs to 20 N.m (15 lb ft). For new iron heads, tighten the spark plugs to 30 N.m (22 lb ft).
  4. Install the spark plug wires. Refer to «Spark Plug Wire Replacement»(ref-186616-S30604988412005083000000) .
IMPORTANTPerform the CKP system variation learn procedure whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure .
  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  2. Disconnect the CKP sensor harness connector.
  3. Remove the CKP sensor mounting bolt.
  4. Remove the CKP sensor.
IMPORTANTWhen installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTCs.
  1. Replace the CKP sensor O-ring.
  2. Lubricate the O-ring with clean engine oil before installing the CKP sensor.
  3. Install the CKP sensor.
  4. Install the CKP sensor mounting bolt. Tighten: Tighten the mounting bolt to 8 N.m (71 lb in).
  5. Connect the CKP sensor harness connector.
  6. Lower the vehicle.
  7. Perform the CKP system variation learn procedure. Refer to «CKP System Variation Learn Procedure»(ref-186616-S39541856672005083000000) .
  1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  2. Disconnect the spark plug wires and ignition coil wire from the distributor. Refer to «Spark Plug Wire Replacement»(ref-186616-S30604988412005083000000) .
  3. Disconnect the camshaft position (CMP) sensor harness connector from the distributor.
  4. Remove the distributor cap screws.
  5. Remove the distributor cap.
  6. Remove the rotor screws.
  7. Remove the rotor.
  8. Align the square slot in the reluctor wheel with the CMP sensor.
  9. Remove the CMP screws.
  10. Remove the CMP sensor.
IMPORTANTDo not use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound.
  1. Insert the CMP sensor through the reluctor wheel slot.
  2. Install new CMP mounting screws. Tighten: Tighten the bolts to 2.2 N.m (20 lb in).
  3. Install the rotor onto the reluctor wheel.
  4. Install new rotor screws. Tighten: Tighten the screws to 2 N.m (18 lb in).
  5. Install the distributor cap.
  6. Install new distributor cap screws. Tighten: Tighten the screws to 2.4 N.m (21 lb in).
  7. Connect the CMP sensor harness connector.
  8. Connect the spark plug wires and ignition coil wire. Refer to «Spark Plug Wire Replacement»(ref-186616-S30604988412005083000000) .
  9. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.

The knock sensor (KS) is located at the top rear of the engine.

  1. Disconnect the negative battery cable.
  2. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  3. Disconnect the KS harness connector (3).
  4. Remove the KS bolt (1).
  5. Remove the KS (2).
  1. Install the knock sensor (2) and bolt (1). Tighten: Tighten the knock sensor bolt to 25 N.m (18 lb ft).
  2. Connect the KS harness connector (3).
  3. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
IMPORTANTDo not try to disassemble the linear EGR valve. Service the EGR valve only as a complete assembly.

Scheme 115

Scheme 115
Scheme 115
IMPORTANTCarefully note the position of the linear EGR valve before removal. Do not rotate the linear EGR valve 180 degrees.
  1. Disconnect the negative battery cable.
  2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186616-S30400857942005083000000) .
  3. Remove the linear EGR harness connector.
  4. Remove the bolts attaching the linear EGR valve to the flange.
  5. Remove the linear EGR valve.
  6. Remove the flange gasket.
  7. Clean the EGR valve gasket surface.
  1. Install the new flange gasket.
  2. Install the linear EGR valve.
  3. Install the bolts retaining the linear EGR valve to the flange. Tighten: Tighten the bolts the first pass to 10 N.m (89 lb in). Tighten the bolts the second pass to 25 N.m (18 lb ft).
  4. Install the EGR valve harness connector.
  5. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186616-S30400857942005083000000) .
  6. Connect the negative battery cable.
  1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  2. Remove the retaining fastener from the EGR pipe bracket.
  3. Loosen the pipe fittings at both ends of the EGR pipe.
  4. Remove the EGR pipe.
  1. Install the EGR pipe in the proper location and start the pipe fittings by hand. Do not fully tighten at this step.
  2. Ensure that the EGR pipe fittings are correctly lined up on the adaptors to the exhaust and the intake manifolds.
  3. Tighten the EGR pipe fittings to the intake manifold and the exhaust manifold. Tighten: Tighten the fitting to the intake manifold to 25 N.m (18 lb ft). Tighten the fitting to the exhaust manifold to 30 N.m (22 lb ft).
  4. Install the retaining fastener to the EGR pipe bracket. Tighten: Tighten the fastener to 25 N.m (18 lb ft).
  5. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  1. Remove the air cleaner assembly end cover clips.
  2. Remove the air cleaner cover from the air cleaner assembly (4).
  3. Remove the element.
  1. Install the element.
  2. Install the cover to the air cleaner assembly (4).
  3. Install the air cleaner assembly end cover clips.
  1. Loosen the duct clamp (1).
  2. Remove the air cleaner assembly bolts (3).
  3. Remove the air cleaner assembly.
  1. Install air cleaner assembly
  2. Install the air cleaner assembly bolts (3). Tighten: Tighten the bolts to 18 N.m (13 lb ft).
  3. Tighten the duct clamp. Tighten: Tighten the clamp to 2 N.m (18 lb in).
  1. Disconnect the negative battery cable.
  2. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  3. Remove the retaining nut (1) from the air cleaner outlet.
  4. Remove the air cleaner outlet duct (2) from the throttle body assembly.
  5. Disconnect the harness connector of the intake air temperature (IAT) sensor.
  6. Loosen the air cleaner outlet duct from the mass air flow (MAF) sensor.
  7. Remove the air cleaner outlet duct.
  1. Install the air cleaner outlet duct to the MAF sensor.
  2. Connect the IAT sensor harness connector.
  3. Install the air cleaner outlet duct (2) on the throttle body assembly.
  4. Tighten the retaining nut (1). Tighten: Tighten the nut 2 N.m (18 lb in).
  5. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  6. Connect the negative battery cable.

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