Home ReviewsRefund Car not listed?
Home/GMC/Savana G2500/GMC Savana G2500 (1996-2013)/Repair manual/Testing & Diagnostics/Engine Control System - 4.8L, 5.3L & 6.0L (Introduction): R…
Contents Wiring diagrams Section: Testing & Diagnostics All sections

Engine Control System - 4.8L, 5.3L & 6.0L (Introduction): Removal & Installation GMC Savana G2500

Testing & Diagnostics ~9781 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.
  1. Disconnect the instrument panel (I/P) harness electrical connector (2).
  2. Release the red connector position assurance (CPA) retainer.
  3. Disconnect the engine wiring harness electrical connector (1).
  4. Remove the throttle actuator control (TAC) module nuts.
  5. Remove the TAC module.
  1. Install the TAC module.
  2. Install the TAC module nuts. Tighten: Tighten the nuts to 9 N.m (80 lb in).
  3. Connect the engine wiring harness electrical connector (1).
  4. Install the red CPA retainer.
  5. Connect the I/P harness electrical connector (2).
  1. Turn OFF the ignition.
  2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  3. Drain the cooling system below the level of the ECT sensor. Refer to «Draining and Filling Cooling System»(ref-186629-S37766623502005083000000) in Engine Cooling.
  4. Lower the vehicle.
  5. Disconnect the electrical connector from the engine coolant temperature (ECT) sensor.
  6. Remove the ECT sensor.
  1. Coat the ECT sensor threads with sealer GM P/N 12346004 (Canadian P/N 10953480) or the equivalent.
  2. Install the ECT sensor. Tighten: Tighten the ECT sensor to 20 N.m (15 lb ft).
  3. Connect the ECT sensor electrical connector.
  4. Refill the engine coolant. Refer to «Draining and Filling Cooling System»(ref-186629-S37766623502005083000000) in Engine Cooling.
IMPORTANTTake 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. Do not drop or roughly handle the MAF/IAT sensor.
  1. Disconnect the MAF/IAT sensor electrical connector.
  2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186613-S40513877012005083000000) .
  3. Loosen the clamp securing the MAF/IAT sensor to the air cleaner duct.
  4. Remove the MAF/IAT sensor bolts from the air cleaner assembly.
  5. Remove the MAF/IAT from the air cleaner.
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 onto the air cleaner housing.
  3. Install the MAF/IAT sensor retaining bolts. Tighten: Tighten the bolts to 11 N.m (97 lb in).
  4. Tighten the clamp securing the MAF/IAT sensor to the air cleaner duct.
  5. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186613-S40513877012005083000000) .
  6. Connect the MAF/IAT electrical connector.
  1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
  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 to the upper intake manifold.
  2. Connect the MAP sensor electrical connector.
  3. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  1. Raise the vehicle.
  2. Disconnect the connector (1) for the HO2S.
  3. Remove the HO2S (2) using a J 39194-B . See «Special Tools and Equipment»(ref-186613-S27122588242005083000000) .
  1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary.
  2. Install the HO2S (2) using a J 39194-B . See «Special Tools and Equipment»(ref-186613-S27122588242005083000000) . 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.
  2. Disconnect the connector (1) for the HO2S.
  3. Remove the HO2S (2) using a J 39194-B . See «Special Tools and Equipment»(ref-186613-S27122588242005083000000) .
  1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary.
  2. Install the HO2S (2) using a J 39194-B . See «Special Tools and Equipment»(ref-186613-S27122588242005083000000) . 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.
  2. Disconnect the connector (1) for the HO2S.
  3. Remove the HO2S (2) using a J 39194-B . See «Special Tools and Equipment»(ref-186613-S27122588242005083000000) .
  1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary.
  2. Install the HO2S (2) using a J 39194-B . See «Special Tools and Equipment»(ref-186613-S27122588242005083000000) . 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.
  2. Disconnect the connector (1) for the HO2S.
  3. Remove the HO2S (2) using a J 39194-B . See «Special Tools and Equipment»(ref-186613-S27122588242005083000000) .
  1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary.
  2. Install the HO2S (2) using a J 39194-B . See «Special Tools and Equipment»(ref-186613-S27122588242005083000000) . Tighten: Tighten the sensor to 42 N.m (31 lb ft).
  3. Connect the HO2S harness connector (1).
  4. Lower the vehicle.
CAUTIONRefer to the Battery Disconnect Caution in Cautions and Notices.

Note. The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent as damage may result.

  1. Disconnect the negative battery cable.
  2. Remove the generator. Refer to «Generator Replacement (4.8L, 5.3L, and 6.0L)»(ref-186595-S30412003562005083000000) or «Generator Replacement (4.3L)»(ref-186595-S10224486642005083000000) in Engine Electrical.
  3. Disconnect the throttle position (TP) sensor electrical connector.
  4. Remove the TP sensor attaching screws (5).
  5. Remove the TP sensor (6).
  6. Remove the TP sensor O-ring seal (7).
  1. Install the TP sensor O-ring seal (7) on the TP sensor (6).
  2. Install the TP sensor on the throttle body with the throttle valve in the closed position. Make sure the TP sensor lever lines up with the TP sensor drive lever on the throttle shaft. NOTE: Refer to «Fastener Notice»(ref-186604-S39582545662005083000000) in Cautions and Notices.
  3. Install the TP sensor attaching screws (5). Tighten: Tighten the screws to 2 N.m (18 lb in).
  4. Connect the TP sensor electrical connector.
  5. Install the generator. Refer to «Generator Replacement (4.8L, 5.3L, and 6.0L)»(ref-186595-S30412003562005083000000) or «Generator Replacement (4.3L)»(ref-186595-S10224486642005083000000) in Engine Electrical.
  6. Connect the negative battery cable.

Note. Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type.

  1. Remove the connector position assurance (CPA) retainer.
  2. Disconnect the accelerator pedal position (APP) sensor electrical connector.
  3. Reposition the carpet to access the lower nut.
  4. Remove the accelerator pedal nuts.
  5. Remove the accelerator pedal assembly.
  1. Install the accelerator pedal assembly.
  2. Install the accelerator pedal nuts. Tighten: Tighten the nuts to 20 N.m (15 lb ft).
  3. Connect the APP sensor electrical connector.
  4. Reposition the carpet.
  5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range.
  6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT).
  7. 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.
  8. Inspect the carpet fit under the accelerator pedal.
  1. Remove the generator. Refer to «Generator Replacement (4.8L, 5.3L, and 6.0L)»(ref-186595-S30412003562005083000000) or «Generator Replacement (4.3L)»(ref-186595-S10224486642005083000000) in Engine Electrical.
  2. Disconnect the idle air control (IAC) valve electrical connector.
  3. Remove the IAC valve attaching screws (4).
  4. Remove the IAC valve (3).
  5. Remove the IAC valve O-ring seal (2).
  6. Clean the IAC valve O-ring sealing surface, the pintle valve seat, and the air passage. Clean the IAC valve using GM cleaner P/N 1052626 or GM X-66A. Use a shop towel or parts brush to remove heavy deposits. If the air passage has heavy deposits, remove the throttle body for complete cleaning. Shiny spots on the pintle or seat are normal and do not indicate misalignment or a bent pintle shaft.
  7. Inspect the IAC valve O-ring for cuts, cracks, or distortion. Replace the O-ring if the O-ring is damaged.
  1. Measure the distance between the tip of the IAC valve pintle and the mounting surface (1). If the distance is more than 28 mm (1.1 in) use finger pressure to slowly retract the pintle. The force required to retract the pintle of a new valve does not cause damage to the valve.
  2. Lubricate the IAC valve O-ring (2) with clean engine oil.
  3. Install the IAC valve O-ring (2) on the IAC valve (3).
  4. Install the IAC valve (3).
  5. Apply LOCTITE 262 to the IAC valve attaching screw threads if necessary. NOTE: Refer to «Fastener Notice»(ref-186604-S39582545662005083000000) in Cautions and Notices.
  6. Install the IAC valve attaching screws (4). Tighten: Tighten the screws to 3 N.m (27 lb in).
  7. Connect the IAC valve electrical connector.
  8. Install the generator. Refer to «Generator Replacement (4.8L, 5.3L, and 6.0L)»(ref-186595-S30412003562005083000000) or «Generator Replacement (4.3L)»(ref-186595-S10224486642005083000000) in Engine Electrical.
  1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186613-S40513877012005083000000) .
  3. Disconnect the accelerator cable from the throttle body lever.
  4. Remove the accelerator cable from the cable bracket.
  5. Unclip the accelerator cable from the engine sight shield mounting bracket and the generator bracket.
  6. Remove the left instrument panel (IP) insulator.
  7. Disconnect the accelerator cable retainer (3) from the accelerator pedal lever (2).
  8. Squeeze the accelerator cable cover tangs (1) and push the cable through the dash panel.
  9. Remove the accelerator cable.
  1. Install the accelerator cable through the dash panel. Snap the accelerator cable cover tangs (1) through the dash panel.
  2. Install the accelerator cable through the slot in the accelerator pedal lever (2).
  3. Seat the retainer (3) in the accelerator pedal lever (2).
  4. Connect the accelerator cable to the throttle body lever.
  5. Slide the accelerator cable into the slot on the accelerator cable bracket. Snap the locking tab into position on the engine sight shield mounting bracket. Clip the accelerator cable onto the generator bracket.
  6. Clip the accelerator cable into the engine sight shield mounting bracket.
  7. Test for complete throttle opening and closing range by operating the accelerator pedal. Also inspect the carpet fit under the accelerator pedal. The throttle should operate freely without binding between full closed throttle and wide open throttle (WOT).
  8. Install the left instrument panel insulator.
  9. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186613-S40513877012005083000000) .
  10. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  1. Remove the left instrument panel (IP) insulator.
  2. Disconnect the accelerator cable retainer (3) from the accelerator pedal lever (2).
  3. Remove the accelerator pedal retaining bolt.
  4. Remove the accelerator pedal from the vehicle.
  1. Install the accelerator pedal.
  2. Install the accelerator pedal retaining bolt. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  3. Install the accelerator cable through the slot in the accelerator pedal lever (2).
  4. Seat the retainer (3) in the accelerator pedal lever (2).
  5. Test for complete throttle opening and closing range by operating the accelerator pedal. Also inspect the carpet fit under the accelerator pedal. The throttle should operate freely and without binding between full closed throttle and wide open throttle (WOT).
  6. Install the left instrument panel insulator.
IMPORTANTDo not for any reason, insert a screwdriver or other small hand tools into the throttle body to hold open the throttle plate, as the wedge inside the throttle body could be damaged.
  1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186613-S40513877012005083000000) .
  2. Disconnect the accelerator control cable and the cruise control cable from the throttle body.
  3. Disconnect the vacuum hose from the throttle body.
  4. Disconnect the throttle position (TP) sensor and idle air control (IAC) valve harness connectors.
  5. Disconnect the coolant hose from the throttle body.
  6. Disconnect the coolant hose from the vapor vent pipe.
  7. Remove the throttle body attaching nuts.
  8. Remove the throttle body and the gasket. Discard the gasket.
  9. Clean the gasket sealing surfaces.
  1. Install the throttle body with a new gasket.
  2. Install the throttle body attaching nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
  3. Connect the coolant hose to the throttle body.
  4. Connect the coolant hose to the vapor vent pipe.
  5. Connect the accelerator control cable and the cruise control cable to the throttle body.
  6. Connect the TP sensor and the IAC valve electrical connectors.
  7. Connect the vacuum hose to the throttle body.
  8. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186613-S40513877012005083000000) .
  9. With the engine OFF, verify that the accelerator pedal moves freely. Depress the accelerator pedal to the floor and release the pedal.
  10. In order to reset the IAC valve, perform the following procedure: Turn ON the ignition for 10 seconds. Turn OFF the ignition for 5 seconds. Start the engine and check for the proper idle speed.
CAUTIONRefer to Gasoline/Gasoline Vapors Caution in Cautions and Notices.
  1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  2. Install the J 34730-1A to the fuel pressure service connection, located on the fuel rail.
  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.
  3. Remove the J 34730-1A from the fuel pressure connection.
  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 the «Fuel Pressure Relief Procedure»(ref-186613-S31315080352005083000000) .
  2. Remove the retainer from the quick-connect fitting.
  3. Blow dirt out of the fitting using compressed air.
  4. Choose the correct tool from the J 37088-A tool set for the size of the fitting. Insert the tool into the female connector, then push inward in order to release the locking tabs.
  5. Pull the connection apart.
  6. Use a clean shop towel in order to wipe off the male pipe end.
  7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required.
  1. Apply a few drops of clean engine oil to the male pipe end.
  2. Push both sides of the fitting together in order to snap the retaining tabs into place.
  3. Once installed, pull on both sides of the fitting in order to make sure the connection is secure.
  4. Install the retainer to the quick-connect fitting.
  1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to «Fuel Pressure Relief Procedure»(ref-186613-S31315080352005083000000) .
  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. 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. 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. 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) or «Fuel Tank Replacement (Passenger/Cargo Van)»(ref-186616-S16667756582005083000000) or «Fuel Tank Replacement (Cutaway Van Rear Tank)»(ref-186616-S37019160122005083000000) .
  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. 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) or «Fuel Tank Replacement (Passenger/Cargo Van)»(ref-186616-S16667756582005083000000) or «Fuel Tank Replacement (Cutaway Van Rear Tank)»(ref-186616-S37019160122005083000000) .
  1. Remove the fuel sender assembly. Refer to «Fuel Sender Assembly Replacement»(ref-186616-S31826379002005083000000) .
  2. Remove the two wire fuel level sensor connectors from the fuel sender assembly.
  3. Using one of two pocket screwdrivers, pull the front retaining tab away from the front of the fuel level sensor while with the second pocket screwdriver push the fuel level sensor away and down from the fuel sender assembly.
  4. Remove the fuel level sensor from the fuel sender assembly.
  1. Install the fuel level sensor (1).
  2. Connect the electrical connector to the fuel tank sender.
  3. Install the fuel sender assembly. Refer to «Fuel Sender Assembly Replacement»(ref-186616-S31826379002005083000000) .
  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
  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
  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. 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. Disconnect the negative battery cable.
  2. Clean all the fuel pipe and hose connections and the surrounding areas before disconnecting in order to avoid possible contamination of the fuel system.
  3. Remove the fuel filler cap.
  4. Drain the fuel below the level of the fuel tank fill hose. Refer to «Fuel Tank Draining Procedure»(ref-186616-S26971635402005083000000) .
  5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  6. Loosen the fuel fill hose clamps (2, 3).
  7. Remove the fuel fill hose (6).
  8. Cap the open end of the fuel tank.
  1. Uncap the fuel tank.
  2. Install the fuel fill hose (6). Tighten: Tighten the fuel fill hose clamps (2, 3) to 2.75 N.m (24 lb in).
  3. Lower the vehicle.
  4. Refill the fuel tank.
  5. Install the fuel filler cap.
  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 air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-186613-S04344705672005083000000) .
  3. Before removal, if necessary, clean the fuel rail assembly with a spray type engine cleaner, use GM X-30A or equivalent. Follow the package instructions. Do not soak fuel rail assembly in any liquid cleaning solvent.
  4. Disconnect the accelerator control cable and the cruise control cable from the cable bracket, if equipped.
  5. Disconnect the cruise control cable engine-end fitting from the stud on the throttle lever, if equipped.
  6. Disconnect the accelerator control cable and the cruise control cable from the throttle body, if equipped.
  7. Remove the upper engine wire harness retainer nut.
  8. Disconnect the evaporative emission (EVAP) purge valve harness connector.
  9. Reposition the upper engine wire harness aside.
  10. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-186613-S31315080352005083000000) .
  11. Mark the electrical connectors to their corresponding injectors to ensure correct sequential injector firing order after reassembly.
  12. Pull the connector position assurance (CPA) (2) on the injector connector up.
  13. Push the tab (1) on the injector connector in.
  14. While pushing the tab (1) on the injector connector in, release the CPA (2).
  15. Disconnect the fuel injector connector electrical connector.
  16. Repeat steps for each injector connector.
  17. Disconnect the fuel feed and return pipes (1, 2) from the fuel rail.
  18. Disconnect the fuel pressure regulator vacuum line.
  19. Loosen the crossover tube to right fuel rail retainer screw (22).
  20. Remove the fuel rail bolts.
  21. Remove the fuel rail.
  22. Remove and discard the fuel injector lower O-ring seals (4) from the injectors (3).
  1. Lubricate the NEW fuel injector lower O-ring seals (4) with clean engine oil.
  2. Install the NEW O-ring seals (4) to the end of each injector (3).
  3. Remove the retaining clip attaching screw (22) and crossover pipe retainer (21) to the right hand fuel rail.
  4. Remove the crossover pipe rail (25) from the right fuel rail (15).
  5. Remove the crossover pipe O-ring (20).
  6. Lubricate a NEW O-ring (20) with clean engine oil.
  7. Install a NEW crossover pipe O-ring (20) on the crossover pipe (25).
  8. Install the crossover pipe (25) into the right fuel rail (15). IMPORTANT: When installing the retaining clip attaching screw for the crossover pipe, always start the screw by hand. This will prevent consequent stripping of the threads in the fuel rail.
  9. Loosely install the crossover pipe retainer (21) and retaining clip attaching screw (22) to the right fuel rail.
  10. Install the fuel rail.
  11. Apply a 5 mm (0.020 in) band of GM P/N 12345382 (Canadian P/N 10953489) threadlock, or equivalent, to the threads of the fuel rail bolts. NOTE: Refer to «Fastener Notice»(ref-186604-S39582545662005083000000) in Cautions and Notices.
  12. Install the fuel rail bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in). Tighten the screw to 3.8 N.m (34 lb in).
  13. Connect the fuel pressure regulator vacuum line.
  14. Connect the fuel feed and return pipes (1, 2) to the fuel rail.
  15. Connect the fuel injector electrical connectors. Install each connector onto the correct injector in order to ensure correct sequential injector firing order. Rotate the injectors as required in order to avoid stretching the wire harness.
  16. Position the upper engine wire harness in place.
  17. Connect the EVAP purge solenoid connector.
  18. Install the retainer nut to the upper engine wire harness. Tighten: Tighten the nut to 5.5 N.m (49 lb in).
  19. Connect the accelerator control cable and the cruise control cable to the cable bracket, if equipped.
  20. Connect the accelerator control cable to the throttle body, if equipped.
  21. Connect the cruise control cable engine-end fitting to the stud on the throttle lever, if equipped.
  22. Install the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-186613-S04344705672005083000000) .
  23. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  24. Use the following procedure in order to inspect for leaks: Turn ON the ignition, with the engine OFF, for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
IMPORTANTThe fuel rail for the 5.3L regular production option (RPO) L59 (VIN Z) is compatible with fuel that has a composition of up to 85 percent Ethanol (E85). Because of this, the fuel rail will be serviced as an entire assembly, that includes both the left and right rail assemblies and the crossover pipe rail.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-186613-S31315080352005083000000) .
  2. Disconnect the fuel feed (1) and the fuel return (2) pipes from the fuel rail.
  3. Remove the fuel return pipe attaching screw (3) and the fuel return pipe retainer (2).
  4. Remove the fuel return pipe (1).
  5. Remove and discard the fuel return pipe O-ring (6).
  6. Remove the fuel pressure connection core assembly (24) from the crossover pipe rail (25).
  7. Remove the retaining clip attaching screw (22) and the crossover fuel pipe retainer clip (21).
  8. Remove the retaining clip attaching screw (4) and the crossover fuel pipe retainer clip (5).
  9. Remove the crossover pipe rail assembly (25) from the left hand rail assembly (14) and the right hand rail assembly (15).
  10. Remove and discard the crossover fuel pipe O-rings (7, 20).
  1. Lubricate the NEW crossover fuel pipe O-rings (7, 20) with clean engine oil.
  2. Install the NEW crossover fuel pipe O-rings (7, 20) onto the crossover pipe rail assembly (25).
  3. Install the crossover pipe rail assembly (25) to the left hand rail assembly (14) and the right hand rail assembly (15). NOTE: Refer to Fastener Notice in Cautions and Notices. IMPORTANT: When installing the retaining clip attaching screws for the crossover pipe, always start them by hand. This will prevent consequent stripping of the threads in the rail.
  4. Install the crossover fuel pipe retainer clip (21). Loosely install the retaining clip attaching screw (22).
  5. Lubricate the NEW fuel return pipe O-ring (6) with clean engine oil.
  6. Install the NEW fuel return pipe O-ring (6) on the fuel return pipe (1).
  7. Install the fuel return pipe (1).
  8. Install the fuel return pipe retainer (2). Loosely install the fuel return pipe attaching screw (3). IMPORTANT: When installing the retaining clip attaching screws for the crossover pipe, always start them by hand. This will prevent consequent stripping of the threads in the rail.
  9. Install the crossover fuel pipe retainer clip (5). Loosely install the retaining clip attaching screw (4). Tighten: Tighten the crossover fuel pipe retainer clip attaching screws to 3.8 N.m (34 lb in). Tighten the fuel return pipe attaching screw to 5 N.m (44 lb in).
  10. Install the fuel pressure connection core assembly (24) to the crossover pipe rail assembly (25).
  11. Connect the fuel return (2) and fuel feed (1) pipes to the fuel rail.
  12. Tighten the fuel fill cap.
  13. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-186595-S11053284922005083000000) in Engine Electrical.
  14. Use the following procedure in order to inspect for leaks: Turn ON the ignition, with the engine OFF, for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
  15. Install the fuel pressure connection cap.
IMPORTANTThe fuel rail for the 5.3L regular production option (RPO) L59 (VIN Z) is compatible with fuel that has a composition of up to 85 percent Ethanol (E85). Because of this, the fuel rail will be serviced as an entire assembly that includes both left and right rail assemblies and the fuel return pipe.
  1. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief Procedure»(ref-186613-S31315080352005083000000) .
  2. Disconnect the fuel feed (1) and fuel return (2) pipes from the fuel rail.
  3. Remove the retaining clip attaching screw (4).
  4. Remove the crossover fuel pipe retainer clip (5).
  5. Remove the fuel return pipe attaching screw (3) and the fuel return pipe retainer (2).
  6. Remove the fuel return pipe (1).
  7. Remove and discard the fuel return pipe O-ring (6).
  1. Lubricate a NEW fuel return pipe O-ring (6) with clean engine oil.
  2. Install the fuel return pipe O-ring (6) onto the fuel return pipe (1).
  3. Install the fuel return pipe (1). NOTE: Refer to the Fastener Notice in Cautions and Notices.
  4. Install the fuel return pipe retainer (2) and the fuel return pipe attaching screw (3).
  5. Install the crossover fuel pipe retainer clip (5).
  6. Install the retaining clip attaching screw (4). Tighten: Tighten the crossover fuel pipe retainer clip attaching screw (4) to 3.8 N.m (34 lb in). Tighten the fuel return pipe attaching screw (3) to 5 N.m (44 lb in).
  7. Connect the fuel return (2) and fuel feed (1) pipes to the fuel rail.
  8. Tighten the fuel fill cap.
  9. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-186595-S11053284922005083000000) in Engine Electrical.
  10. Use the following procedure in order to inspect for leaks: Turn ON the ignition, with the engine OFF, for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
  11. Install the fuel pressure connection cap.

Note. Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method.

IMPORTANTThe Denso fuel injectors that are installed in the 5.3L (L59) E85 application will not have O-rings and retaining clips serviced separately. Therefore, the fuel injectors will be replaced whenever an O-ring or clips needs to be replaced.
IMPORTANTThe engine oil may be contaminated with fuel if the fuel injectors are leaking.
  1. Remove the fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-186613-S16571797702005083000000) .
  2. Remove the fuel injector retainer clip (19).
  3. Remove the fuel injector (17).
  4. Discard the injector retainer clip (1).
  5. Remove and discard the fuel injector O-ring seals (2, 4) from the injector.
IMPORTANTWhen ordering new fuel injectors, you must order the correct injector for the application being serviced.
  1. The fuel injector (1) is stamped with a part number identification (2). A four-digit build date code (3), which indicates the month (4), day (5), year (6), and the shift (7) that built the fuel injector.
  2. Lubricate the NEW fuel injector O-ring seals (2, 4) with clean engine oil.
  3. Install the NEW injector O-ring seals onto the fuel injector.
  4. Install a NEW retainer clip (1) onto the fuel injector.
  5. Install the fuel injector (17) into the fuel rail injector socket with the electrical connector facing outward. The retainer clip (19) locks onto a flange on the fuel rail injector socket.
  6. Install the fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-186613-S16571797702005083000000) .
  1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186613-S40513877012005083000000) .
  2. Push the evaporative emission (EVAP) pipe quick connect fitting retainer inward.
  3. Disconnect the EVAP pipe (2) from the EVAP purge solenoid (1).
  4. Disconnect the EVAP purge solenoid electrical connector.
  5. Remove the EVAP purge solenoid mount bolt (2).
  6. Remove the EVAP purge solenoid (3) and the insulator (1) from the engine.
  1. Install the insulator (1) on the EVAP canister purge valve (3).
  2. Install the EVAP canister purge valve (3) to the engine. NOTE: Refer to «Fastener Notice»(ref-186604-S39582545662005083000000) in Cautions and Notices.
  3. Install the EVAP canister purge valve mount bolt (2). Tighten: Tighten the EVAP canister purge valve mount bolt to 10.5 N.m (93 lb in).
  4. Connect the EVAP pipe (2) to the EVAP canister purge valve (1).
  5. Connect the EVAP canister purge valve electrical connector.
  6. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186613-S40513877012005083000000) .
  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.
  1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  2. Disconnect the spark plug wires at the ignition coils.
  3. Disconnect the ignition coil harness connector.
  4. Remove the ignition coil mounting bolts.
  5. Remove the ignition coil.
  1. Install the ignition coil to the bracket.
  2. Install the ignition coil mounting bolts. Tighten: Tighten the ignition coil mounting bolts to 8 N.m (71 lb in).
  3. Connect the ignition coil harness connector.
  4. Connect the spark plug wires at the ignition coils.
  5. 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 each spark plug wire 1/2 turn. Pull only on the boot in order to remove the wire from each spark plug.
  3. Disconnect the spark plug wire from the ignition coil. Twist each spark plug boot 1/2 turn. Pull only on the boot in order to remove the wires from the ignition coil.
  1. Install the spark plug wires at the ignition coil.
  2. Install the spark plug wire to each spark plug.
  3. Inspect the wires for proper installation: Push sideways on each boot in order to inspect the seating. Reinstall any loose boot.
  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-186613-S16055318762005083000000) .
  2. Loosen each spark plug 1 or 2 turns.
  3. Brush or air blast away any dirt from around the spark plugs.
  4. Remove the spark plugs 1 at a time. Place each plug in a tray marked with the corresponding cylinder numbers.
  1. Properly position each spark plug washer.
  2. Inspect each spark plug gap. Adjust each plug as needed. Specification: Spark plug gap: 1.524 mm (0.060 in)
  3. Hand start the spark plugs in the corresponding cylinders.
  4. Tighten the spark plugs. Tighten: For used heads tighten the spark plugs to 15 N.m (11 lb ft). For new aluminum heads tighten the spark plugs to 20 N.m (15 lb ft). For new iron heads, tighten the spark plugs to 30 N.m (22 lb ft).
  5. Install the spark plug wires. Refer to «Spark Plug Wire Replacement»(ref-186613-S16055318762005083000000) .
CAUTIONBefore servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.
IMPORTANTPerform the CKP System Variation Learn Procedure when the CKP sensor is removed or replaced.
  1. Refer to Battery Disconnect Caution in Cautions and Notices. Disconnect the negative battery cable.
  2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
  3. Remove the starter. Refer to «Starter Motor Replacement (4.8L, 5.3L, and 6.0L)»(ref-186595-S21564992502005083000000) or «Starter Motor Replacement (4.3L)»(ref-186595-S07149347622005083000000) in Engine Electrical.
  4. Disconnect the crankshaft position (CKP) sensor electrical connector.
  5. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine.
  6. Remove the CKP sensor retaining fastener.
  7. Remove the CKP sensor.
  1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the CKP sensor retaining fastener. Tighten: Tighten the fastener to 25 N.m (18 lb ft).
  3. Connect the CKP sensor electrical connector.
  4. Install the starter. Refer to «Starter Motor Replacement (4.8L, 5.3L, and 6.0L)»(ref-186595-S21564992502005083000000) or «Starter Motor Replacement (4.3L)»(ref-186595-S07149347622005083000000) in Engine Electrical.
  5. Lower the vehicle.
  6. Connect the negative battery cable.
  7. Perform the CKP system variation learn procedure. Refer to «CKP System Variation Learn Procedure»(ref-186613-S37788406182005083000000) .
IMPORTANTClean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine.
  1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  2. Disconnect the CMP sensor electrical connector.
  3. Remove the CMP sensor bolt.
  4. Remove the CMP sensor.
  1. Install the CMP sensor.
  2. Install the CMP sensor bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  3. Connect the CMP sensor electrical connector.
  4. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
  1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-186639-S27821230132005083000000) in Engine Mechanical.
  2. Remove the KS wiring harness assembly.
  3. Remove the KS.
  1. Install the KS. Tighten: Torque the sensor to 20 N.m (15 lb ft).
  2. Install the KS wiring harness assembly.
  3. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-186639-S27821230132005083000000) in Engine Mechanical.
IMPORTANTDo not try to disassemble the exhaust gas recirculation (EGR) valve. Service the valve only as a complete assembly.
IMPORTANTCarefully note the position of the EGR valve before removal. Do not rotate the EGR valve 180 degrees.
  1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186613-S40513877012005083000000) .
  2. Disconnect the EGR electrical connector.
  3. Remove the valve to flange attaching fasteners.
  4. Remove the EGR valve.
  5. Remove the flange gasket.
  6. Clean the EGR valve gasket surface.
  1. Install the new flange gasket
  2. Install the EGR valve. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the valve to flange fasteners. Tighten: Tighten the fasteners the first time to 10 N.m (89 lb in) each. Tighten the fasteners a final time to 25 N.m (18 lb ft) each.
  4. Connect the electrical connector.
  5. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186613-S40513877012005083000000) .
  1. Remove the exhaust gas recirculation (EGR) valve. Refer to «Exhaust Gas Recirculation (EGR) Valve Replacement»(ref-186613-S30415592462005083000000) .
  2. Remove the EGR pipe (2) to intake manifold fasteners.
  3. Remove the EGR pipe to exhaust manifold fasteners.
  4. Remove the EGR pipe mounting fasteners from the right cylinder head.
  5. Remove the EGR pipe.
  1. Install the EGR pipe.
  2. Install the EGR pipe mounting fasteners to the right cylinder head. Tighten: Tighten the fasteners to 50 N.m (37 lb ft).
  3. Install the EGR pipe (2) to exhaust manifold fasteners. Tighten: Tighten the fasteners to 25 N.m (18 lb ft).
  4. Install the EGR pipe to intake manifold fasteners. Tighten: Tighten the fasteners to 12 N.m (106 lb in).
  5. Install the EGR valve. Refer to «Exhaust Gas Recirculation (EGR) Valve Replacement»(ref-186613-S30415592462005083000000) .
  6. Install air intake duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-186613-S04344705672005083000000) .
  1. Unclip the air filter cover (2).
  2. Lift and rotate the top cover (2) of the air cleaner housing to gain access to the air filter element.
  3. Pull out the air filter element.
  4. Inspect the air filter element for dust, dirt, or water. Clean or replace the air filter element if required.
  1. Install the air filter element into the air cleaner housing (1).
  2. Rotate and install the top cover (2) to the air cleaner housing (1).
  1. Remove the air intake duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-186613-S04344705672005083000000) .
  2. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor (5) connector.
  3. Loosen the clamp securing the MAF/IAT sensor to the air cleaner assembly.
  4. Remove the MAF/IAT sensor.
  5. Pull up on the air cleaner assembly (1) to release the retainers from the air cleaner adaptor (2).
  1. Position the air cleaner assembly (4) onto the air cleaner adaptor. Ensure the retainers fit properly into the air cleaner adaptor (3).
  2. Secure the air cleaner assembly (4) onto the air cleaner adaptor (3).
  3. Install the MAF/IAT sensor (5) to the air cleaner assembly.
  4. Secure the clamps at the MAF/IAT sensor and the air cleaner assembly.
  5. Connect the MAF/IAT connector (5).
  6. Install the air intake duct.
  1. Loosen the clamp and separate the air cleaner resonator outlet duct (1) from the mass air flow/intake air temperature (MAF/IAT) sensor assembly.
  2. Loosen the clamp and separate the air cleaner resonator outlet duct from the throttle body assembly.
  3. Remove the air cleaner resonator outlet duct.
  1. Install the air cleaner resonator outlet duct to the throttle body assembly and the MAF/IAT sensor assembly.
  2. Tighten the clamps at the throttle body assembly and the MAF/IAT sensor assembly.

More articles — Engine Control System - 4.8L, 5.3L & 6.0L (Introduction)