Engine Controls - (Introduction) - 4.8L, 5.3L, and 6.0L: Removal & Installation Hummer H2 I

Powertrain Control Module (PCM) Replacement

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

1. Remove 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.
2. The 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. Release the PCM cover mounting holes away from the mounting tabs on the PCM mounting bracket.
3. Release the PCM cover from the mounting bracket.
4. Remove the PCM cover.
5. Loosen both PCM connector retaining bolts.
6. Disconnect the PCM harness connectors.
7. Release the spring latch from the PCM.
8. Release the PCM mounting tabs from the PCM.
9. Remove the PCM from the engine compartment.

Installation Procedure

1. Install the PCM to the PCM mounting bracket ensuring that the mounting tabs are engaged.
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. Install the PCM cover to the PCM mounting bracket, ensuring the mounting tabs on the PCM mounting bracket are engaged into the mounting holes in the PCM cover.
5. If a new PCM is being installed, program the PCM. Refer to «Service Programming System (SPS)»(ref-187214-S16668739102005083100000) in Programming.

1. Remove the left hand corner brace from the cowl.
2. Remove the TAC module mounting nuts.
3. Disconnect the TAC module electrical connectors from the TAC module.

1. Connect the TAC module electrical connectors to the TAC module.
2. Install the TAC module onto the studs and install the mounting nuts. Tighten: Tighten the TAC mounting nuts to 9 N.m (80 lb in).
3. Install the left hand corner brace. Tighten: Tighten the corner brace bolts to 25 N.m (18 lb ft).

1. Turn OFF the ignition.
2. Drain the cooling system below the level of the ECT sensor. Refer to «Draining and Filling Cooling System»(ref-187257-S14804005252005083100000) in Engine Cooling.
3. Disconnect the electrical connector from the engine coolant temperature (ECT) sensor.
4. 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-187257-S14804005252005083100000) in Engine Cooling.

1. Remove air intake resonator. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-187222-S15189587742005083100000) .
2. Disconnect the MAF/IAT sensor electrical connector.
3. Loosen the clamp securing the MAF/IAT sensor to the air cleaner housing.
4. Remove the MAF/IAT sensor from the air cleaner assembly.

1. Locate the air flow direction arrow (2) on the MAF/IAT sensor.
2. Install the MAF/IAT sensor on to the air cleaner housing.
3. Tighten the clamp securing the MAF/IAT sensor to the air cleaner housing.
4. Connect the MAF/IAT electrical connector.
5. Install air intake resonator. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-187222-S15189587742005083100000) .

1. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement (6.0L (LQ4))»(ref-187255-S34927328222005083100000) in Engine Mechanical.
2. Remove the engine sight shield bracket bolts. Position the bracket to the side
3. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
4. Remove the MAP sensor (1) from the intake manifold.

1. Install the MAP sensor (1). Push the MAP sensor down in order to engage the sensor into the retainer.
2. Connect the MAP sensor electrical connector.
3. Position the engine harness and sight shield bracket to the intake manifold.
4. Install the engine sight shield bracket bolts. Tighten: Tighten the bracket bolts to 10 N.m (89 lb in).
5. Install the engine sight shield. Refer to «Engine Sight Shield Replacement (6.0L (LQ4))»(ref-187255-S34927328222005083100000) in Engine Mechanical.

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-187222-S32097088622005083100000) .

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-187222-S32097088622005083100000) . 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-187222-S32097088622005083100000) .

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-187222-S32097088622005083100000) . 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-187222-S32097088622005083100000) .

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-187222-S32097088622005083100000) . 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-187222-S32097088622005083100000) .

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-187222-S32097088622005083100000) . Tighten: Tighten the sensor to 42 N.m (31 lb ft).
3. Connect the HO2S harness connector (1).
4. Lower the vehicle.

Scheme 31

1. Remove the left instrument panel (I/P) lower closeout insulator panel.
2. Disconnect the accelerator pedal position (APP) sensor harness connector. Remove the accelerator pedal mounting bolts.
3. Remove the APP assembly.

1. Install the APP assembly to the steering column support bracket.
2. Install the accelerator pedal mounting bolts. Tighten: Tighten the accelerator pedal mounting bolts to 20 N.m (15 lb ft).
3. Connect the APP sensor harness connector.
4. Verify that the vehicle meets the following conditions: The vehicle is not in a Reduced Engine Power mode. The ignition is ON. The engine is OFF.
5. Connect a scan tool in order to test for a proper throttle-opening and throttle-closing range.
6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT).
7. Inspect the carpet fit under the accelerator pedal.
8. Install the left I/P lower closeout insulator panel.

1. Partially drain the cooling system in order to allow the hoses at the throttle body to be removed. Refer to «Draining and Filling Cooling System»(ref-187257-S14804005252005083100000) in Engine Cooling.
2. Remove the air intake duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-187222-S15189587742005083100000) .
3. Disconnect the throttle actuator motor harness connector.
4. Disconnect the coolant hoses from the throttle body.
5. Remove the throttle body attaching bolts.
6. Remove the throttle body and the gasket.
7. Discard the throttle body gasket.
8. Inspect the crankcase ventilation hose and the tube. Replace any damaged components.

1. Install a new throttle body gasket.
2. Install the throttle body assembly.
3. Install the throttle body attaching bolts. Tighten: Tighten the throttle body bolts to 10 N.m (89 lb in).
4. Connect the coolant hoses to the throttle body.
5. Connect the TAC harness connector.
6. Install the air intake duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-187222-S15189587742005083100000) .
7. Connect the intake air temperature sensor harness connector.
8. Refill the cooling system. Refer to «Draining and Filling Cooling System»(ref-187257-S14804005252005083100000) in Engine Cooling.
9. Verify that the vehicle meets the following conditions: The vehicle is not in a Reduced Engine Power mode. The ignition is ON. The engine is OFF.
10. Connect a scan tool in order to test for a proper throttle-opening and throttle-closing range.
11. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT).
12. Start the engine.
13. Inspect for coolant leaks.

1. Install the fuel pressure gauge to the fuel pressure service connection, located on the fuel rail.
2. Turn ON the ignition.
3. Place the bleed hose of the fuel pressure gauge into an approved gasoline container.
4. Open the bleed valve on the fuel pressure gauge in order to bleed the air from the fuel pressure gauge.
5. Command the fuel pump ON with a scan tool.
6. Close the bleed valve on the fuel pressure gauge.
7. Inspect for fuel leaks.

1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the «Fuel Pressure Relief Procedure»(ref-187222-S40474852822005083100000) .
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. See «Special Tools and Equipment»(ref-187222-S32097088622005083100000) .
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-187222-S40474852822005083100000) .
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. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief Procedure»(ref-187222-S40474852822005083100000) .
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
3. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-187222-S32632501792005083100000) .
4. Remove the fuel fill pipe from the fuel tank.
5. Disconnect the chassis fuel pipes at the fuel filter.
6. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.
7. Disconnect the EVAP vent pipe at the fuel canister.
8. Loosen the vent hose and filler hose clamp.
9. Disconnect the vent hose and filler hose from the pipe.
10. Remove the fuel tank protective shield.
11. With the aid of an assistant, support the fuel tank.
12. Remove the fuel tank strap attaching bolts.
13. Remove the fuel tank straps.
14. Carefully lower the rear of the fuel tank slightly.
15. Disconnect the fuel sender and the fuel pressure sensor electrical connectors.
16. Remove the fuel tank.
17. Place the fuel tank in a suitable work area.
18. Remove the fuel feed and return pipes from the fuel sender and the retaining clips.
19. Remove the fuel sender assembly from the fuel tank. Refer to «Fuel Sender Assembly Replacement»(ref-187222-S36545567562005083100000) .
20. Remove the EVAP pipe from the fuel tank roll over valves and the retaining clips.

1. Connect the EVAP pipe to the fuel tank roll over valves and the retaining clips.
2. Install the fuel sender assembly to the fuel tank. Refer to «Fuel Sender Assembly Replacement»(ref-187222-S36545567562005083100000) .
3. Connect the fuel feed and return pipes to the fuel sender and the retaining clips.
4. Install the fuel fill hose and the vent hose to the fuel tank. Tighten: Tighten the hose clamps to 2.5 N.m (22 lb in).
5. With the aid of an assistant, support and partially raise the fuel tank front end first.
6. Connect the fuel sender and the fuel pressure sensor electrical connectors.
7. Fully raise the fuel tank.
8. Install the fuel tank straps.
9. Install the fuel tank strap attaching bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
10. Connect the fuel fill hose and the vent hose to the pipes. Tighten: Tighten the fuel fill hose clamp to 2.5 N.m (22 lb in). Tighten the vent hose clamp to 2.5 N.m (22 lb in).
11. Install the fuel fill pipe to the fuel tank.
12. Remove the caps from the fuel and EVAP pipes.
13. Connect the EVAP vent pipe to the fuel canister.
14. Connect the chassis fuel pipes at the fuel filter.
15. Install the fuel tank protective shield. Tighten: Tighten fuel tank protective shield bolts to 25 N.m (18 lb ft).
16. Lower the vehicle.
17. Refill the fuel tank.
18. Install the fuel filler cap.
19. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-187208-S04260183982005083100000) in Engine Electrical.
20. 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.
21. Install the engine sight shield. Refer to «Engine Sight Shield Replacement (6.0L (LQ4))»(ref-187255-S34927328222005083100000) in Engine Mechanical.

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-187222-S10727559052005083100000) .
2. Remove the fuel pressure sensor.

1. Install the fuel pressure sensor.
2. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-187222-S10727559052005083100000) .

1. Remove the fuel sender. Refer to «Fuel Sender Assembly Replacement»(ref-187222-S36545567562005083100000) .
2. Place the fuel sender on a clean work surface.
3. Disconnect the fuel level sensor electrical connector from the module connector.
4. Remove the fuel level sensor retaining clip.
5. Squeeze the retaining tabs together in order to slide the fuel lever sensor off of the reservoir.

1. Slide the fuel lever sensor (3) onto the reservoir until the retaining tabs snap into place.
2. Connect the fuel level sensor electrical connectors (1) to the module connector.
3. Install the fuel sender. Refer to «Fuel Sender Assembly Replacement»(ref-187222-S36545567562005083100000) .

1. Clean all the fuel pipe and hose connections and the surrounding areas before disconnection in order to avoid possible contamination of the fuel system.
2. Remove the fuel filler cap.
3. Drain the fuel below the level of the fuel filler hose. Refer to «Fuel Tank Draining Procedure»(ref-187222-S32632501792005083100000) .
4. Remove the fuel fill pipe housing/bezel to fuel fill pipe bolts.
5. Remove housing/bezel by rotating clockwise.
6. Remove the left rear wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-187238-S08699841412005083100000) in Body Rear End.
7. Disconnect the rear axle vent and air spring compressor hoses from the retainer on the fuel fill pipe, if applicable.
8. Loosen the fuel vent hose to fuel tank clamp.
9. Loosen the fuel fill hose to fuel tank clamp.
10. Disconnect the fuel fill pipe bracket bolt.
11. Disconnect the fuel fill and vent hoses from the fuel tank.
12. Remove the fuel fill and vent pipe and hose assembly.
13. Cap the open end of the fuel tank.

1. Uncap the fuel tank.
2. Install the fuel fill and vent pipe hose assembly to the fuel tank. Tighten: Tighten the vent hose clamp and the fuel fill pipe clamp to 2.5 N.m (22 lb in).
3. Install the fuel fill pipe bracket bolt. Tighten: Tighten the bolt to 12 N.m (106 lb in).
4. Connect the rear axle vent and air spring compressor hoses to the retainer on the fuel fill pipe, if applicable.
5. Install the left rear wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-187238-S08699841412005083100000) in Body Rear End.
6. Lower the vehicle.
7. Install fill pipe/housing bezel by fitting into offset slots and rotating clockwise.
8. Install the fuel fill pipe housing to the fuel fill pipe bolts. Tighten: Tighten the fuel fill pipe housing to fuel fill pipe bolts to 2.3 N.m (20 lb in).
9. Refill the fuel system.
10. Install the fuel filler cap.

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-187222-S10727559052005083100000) .
2. Remove fuel lines from sender assembly. Refer to «Fuel Hose/Pipes Assembly Replacement»(ref-187222-S19280876422005083100000) .
3. Remove the fuel sender assembly retaining ring using the J 44402 .
4. Remove the fuel sender assembly and the seal. Discard the seal.
5. Clean the fuel sender sealing surfaces.

1. Install the new seal on the fuel tank.
2. Install the fuel sender assembly into the fuel tank. NOTE: Refer to Fastener Notice in Cautions and Notices.
3. Install the fuel sender assembly retaining ring using the J 44402 .
4. Install fuel lines to sender assembly. Refer to «Fuel Hose/Pipes Assembly Replacement»(ref-187222-S19280876422005083100000) .
5. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-187222-S10727559052005083100000) .

1. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief Procedure»(ref-187222-S40474852822005083100000) .
2. Clean all the fuel pipe connections and the surrounding areas before disconnecting the pipes in order to avoid possible contamination of the fuel system.
3. Disconnect the fuel feed and return pipes (1, 2) from the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-187222-S15364037262005083100000) .
4. Cap the fuel rail pipes.
5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
6. Remove the left hand catalytic converter. Refer to «Catalytic Converter Replacement (Right Hand)»(ref-187284-S33119295632005083100000) in Engine Exhaust.
7. Remove the fuel pipes from the bellhousing stud clip (4).
8. Remove the fuel pipes from the transmission bracket clip.
9. Disconnect the chassis fuel feed hose at the fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-187222-S08226576452005083100000) .
10. Cap the rear fuel pipes.
11. Note the position of the fuel pipes for aid in installation.
12. Remove the fuel pipes from the retaining clips.
13. Remove the fuel pipes.

1. Install the fuel pipes into the retaining clips.
2. Remove the caps from the rear fuel pipes.
3. Connect the chassis fuel feed hose at the fuel filter. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-187222-S08226576452005083100000) .
4. Install the fuel pipes into the transmission bracket clip.
5. Install the fuel pipes into the bellhousing stud clip (4).
6. Lower the vehicle.
7. Install the left hand catalytic converter. Refer to «Catalytic Converter Replacement (Right Hand)»(ref-187284-S33119295632005083100000) in Engine Exhaust.
8. Remove the caps from the fuel rail pipes.
9. Connect the fuel feed and return pipes (1, 2) to the fuel rail.
10. Tighten the fuel filler cap.
11. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-187208-S04260183982005083100000) in Engine Electrical.
12. 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.
13. Install the engine sight shield. Refer to «Engine Sight Shield Replacement (6.0L (LQ4))»(ref-187255-S34927328222005083100000) in Engine Mechanical.

1. Clean all the fuel pipe and hose connections and the surrounding areas before disconnecting in order to avoid possible contamination of the fuel system.
2. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-187222-S10727559052005083100000) .
3. Remove the rear fuel feed pipe and the rear fuel return pipe from the fuel sender and the fuel tank clips.
4. Cap the fuel pipes in order to prevent possible fuel system contamination.

1. Remove the caps from the fuel pipes.
2. Connect the rear fuel feed pipe and the rear fuel return pipe to the fuel sender and the fuel tank clips.
3. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-187222-S10727559052005083100000) .

1. Clean all the fuel pipe and hose connections and the surrounding areas before disconnecting in order to avoid possible contamination of the fuel system.
2. Drain the fuel below the level of the filler tube and hose assembly. Refer to «Fuel Tank Draining Procedure»(ref-187222-S32632501792005083100000) .
3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
4. Loosen the fuel fill hose clamp at the fuel tank.
5. Loosen the fuel fill hose clamp at the fuel fill pipe.
6. Remove the fuel fill hose and the hose clamps.
7. Cap the fuel tank opening.

1. Uncap the fuel tank opening.
2. Install the fuel fill hose and the hose clamps to the fuel fill pipe. Tighten: Tighten the hose clamps to 2.5 N.m (22 lb in).
3. Lower the vehicle.
4. Refill the fuel system.

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-187222-S40474852822005083100000) .
2. Remove the wire harness bracket nut (2).
3. Disconnect the evaporative emission (EVAP) purge solenoid electrical connector (1).
4. Disconnect the generator electrical connector (3).
5. Disconnect the following electrical connectors: Manifold absolute pressure (MAP) sensor (1) Knock sensor (2)
6. Remove the knock sensor harness connector from the intake manifold.
7. Disconnect the electronic throttle control (ETC) electrical connector (2). Perform the following: Disengage the gray retainer. Push down the black clip. Disconnect the connector.
8. Remove the connector position assurance (CPA) retainer (5).
9. Disconnect the following electrical connectors from the right side of the engine: Main coil (4) Fuel injectors (3)
10. Remove the harness clips from the fuel rail (1).
11. Remove the CPA retainer from the left side of the engine.
12. Disconnect the following electrical connectors from the left side of the engine: Main coil (2) Fuel injectors
13. Remove the harness clips from the fuel rail (1).
14. Reposition the engine wire harness aside.
15. Perform the following steps in order to disconnect the fuel injector electrical connectors: Mark the connectors to their corresponding injectors to ensure correct reassembly. Pull the CPA retainer (2) on the connector up one click. Push the tab (1) on the connector in. Disconnect the fuel injector electrical connector. Repeat the steps for each injector electrical connector.
16. Remove the positive crankcase ventilation (PCV) hose.
17. Disconnect the fuel feed pipe (1) from the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-187222-S15364037262005083100000) .
18. Remove the fuel rail bolts.
19. Remove the fuel rail.
20. Remove the fuel injector lower O-ring seal (4) from each injector, if necessary.
21. Discard the O-ring seal.

1. Lubricate NEW fuel injector lower O-ring seals (4) with clean engine oil.
2. Install the NEW O-ring seals (4) onto each injector, if necessary.
3. Install the fuel rail.
4. Apply a 5 mm (0.2 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the fuel rail bolts.
5. Install the fuel rail bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
6. Connect the fuel feed pipe (1) to the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-187222-S15364037262005083100000) .
7. Install the PCV hose.
8. Perform the following steps in order to connect the fuel injector electrical connectors: Install the connectors to their corresponding injectors to ensure correct reassembly. Connect the fuel injector electrical connector. Push the CPA retainer (2) on the connector in one click. Repeat the steps for each injector electrical connector.
9. Position the engine wire harness.
10. Connect the following electrical connectors to the left side of the engine: Main coil (2) Fuel injectors
11. Install the harness clips to the fuel rail (1).
12. Install the CPA retainer.
13. Connect the following electrical connectors to the right side of the engine: Main coil (4) Fuel injectors (3)
14. Install the CPA retainer (5).
15. Install the harness clips to the fuel rail (1).
16. Connect the ETC electrical connector (2). Perform the following: Connect the connector. Engage the gray retainer.
17. Connect the following electrical connectors: MAP sensor (1) Knock sensor (2)
18. Install the knock sensor harness connector to the intake manifold.
19. Connect the EVAP purge solenoid electrical connector (1).
20. Connect the generator electrical connector (3).
21. Install the wire harness bracket nut (2). Tighten: Tighten the nut to 5 N.m (44 lb in).
22. Tighten the fuel fill cap.
23. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-187208-S04260183982005083100000) in Engine Electrical.
24. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.

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.

1. Remove the fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-187222-S18676519662005083100000) .
2. Remove the fuel injector retainer clip (19).
3. Remove the fuel injector (17).
4. Discard the fuel injector retainer clip (1).
5. Remove and discard the fuel injector O-ring seals (2, 4) from the injector.

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 fuel 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 on to a flange on the fuel rail injector socket.
6. Install the fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-187222-S18676519662005083100000) .

1. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement (6.0L (LQ4))»(ref-187255-S34927328222005083100000) in Engine Mechanical.
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-187216-S26822158702005083100000) 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 engine sight shield. Refer to «Engine Sight Shield Replacement (6.0L (LQ4))»(ref-187255-S34927328222005083100000) in Engine Mechanical.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
2. Disconnect the vent pipe from the evaporative emission (EVAP) canister vent valve.
3. Disconnect the EVAP canister vent valve electrical connector.
4. Detach the EVAP canister vent valve from the EVAP canister vent valve bracket.

1. Install the EVAP canister vent valve to the EVAP canister vent valve bracket.
2. Connect the EVAP canister vent valve electrical connector.
3. Connect the vent pipe to the EVAP canister vent valve.
4. Lower the vehicle.

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 (2) at the EVAP canister purge solenoid (1).
3. Disconnect the engine compartment EVAP pipe (3) at the chassis EVAP pipe.
4. Remove the EVAP pipe from the engine.
5. Cap the EVAP canister purge solenoid and the chassis EVAP pipe in order to prevent possible EVAP system contamination.

1. Remove the caps from the EVAP canister purge solenoid and the chassis EVAP pipe.
2. Install the EVAP pipe on the engine.
3. Connect the engine compartment EVAP pipe (3) to the chassis EVAP pipe.
4. Connect the engine compartment EVAP pipe (2) to the EVAP canister purge solenoid (1).

1. Clean all the EVAP pipe connections and the surrounding areas before disconnecting the pipes in order to avoid possible contamination of the EVAP system.
2. Disconnect the engine compartment EVAP pipe (6) from the chassis EVAP pipe (3).
3. Cap the engine compartment EVAP pipe.
4. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
5. Remove the left hand catalytic converter. Refer to «Catalytic Converter Replacement (Right Hand)»(ref-187284-S33119295632005083100000) in Engine Exhaust.
6. Remove the EVAP pipe from the bellhousing stud clip (4).
7. Remove the EVAP pipe from the transmission bracket clip.
8. Disconnect the rear EVAP purge pipe from the EVAP canister.
9. Cap the rear EVAP purge pipe.
10. Note the position of the EVAP pipe for aid in installation.
11. Remove the EVAP pipe from the retaining clips.
12. Remove the EVAP pipe.

1. Install the EVAP pipe into the retaining clips.
2. Remove the cap from the rear EVAP pipe.
3. Connect the rear EVAP purge pipe to the EVAP canister.
4. Install the EVAP pipe into the transmission bracket clip.
5. Install the EVAP pipe into the bellhousing stud clip (4).
6. Install the left hand catalytic converter. Refer to «Catalytic Converter Replacement (Right Hand)»(ref-187284-S33119295632005083100000) in Engine Exhaust.
7. Lower the vehicle.
8. Remove the cap from the engine compartment EVAP pipe.
9. Connect the engine compartment EVAP pipe (6) to the chassis EVAP pipe (3).

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
2. Clean all the EVAP pipe connections and the surrounding areas before disconnecting in order to avoid possible contamination of the EVAP system.
3. Disconnect the EVAP vent pipe at the EVAP canister.
4. Disconnect the EVAP vent pipe at the EVAP vent valve.
5. Remove the EVAP vent pipe from the mounting clips (1,3,4, and 5).
6. Cap the EVAP vent valve and the EVAP canister in order to prevent possible EVAP system contamination.

1. Remove the caps from the EVAP vent valve and the EVAP canister.
2. Connect the EVAP vent pipe (2) to the EVAP vent valve.
3. Connect the EVAP vent pipe to the EVAP canister.
4. Install the EVAP vent pipe into the mounting clips (1,3,4, and 5).
5. Lower the vehicle.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-187222-S40474852822005083100000) .
3. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-187222-S32632501792005083100000) .
4. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
5. Clean all fuel and EVAP pipe and hose connections and the surrounding areas before disconnection in order to avoid possible contamination of the fuel system.
6. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-187222-S10727559052005083100000) .
7. Remove the rear EVAP pipe from the fuel sender, the fuel tank roll over valve and the fuel tank clips.
8. 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. Connect the rear EVAP pipe to the fuel sender, the fuel tank roll over valve, and the fuel tank clips.
3. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-187222-S10727559052005083100000) .
4. Lower the vehicle.
5. Refill the fuel tank.
6. Connect the negative battery cable.
7. Tighten the fuel filler cap.
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. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
2. Disconnect EVAP solenoid electrical connector.
3. Remove the evaporative emission (EVAP) canister mount bolts.
4. Disconnect the pipes at the EVAP canister.
5. Remove the EVAP canister from the vehicle.

1. Install the EVAP canister to the vehicle.
2. Connect EVAP solenoid electrical connector.
3. Install the EVAP canister mounting bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Connect the pipes to the EVAP canister.
5. Lower the vehicle.

1. Disconnect the spark plug wires at the ignition coils.
2. Disconnect the ignition coil harness connector.
3. Remove the ignition coil mounting bolts.
4. 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.

1. Disconnect the spark plug wire at each spark plug. Twist each spark plug 1/2 turn. Pull only on the boot in order to remove the wire from each spark plug.
2. 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.

1. Remove the spark plug wires. Refer to «Spark Plug Wire Replacement»(ref-187222-S41507871772005083100000) .
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-187222-S41507871772005083100000) .

1. Disconnect the negative battery cable.
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
3. Remove the starter. Refer to «Starter Motor Replacement»(ref-187208-S22382514562005083100000) 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 bolt.
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 bolt to 25 N.m (18 lb ft).
3. Connect the CKP sensor electrical connector.
4. Install the starter. Refer to «Starter Motor Replacement»(ref-187208-S22382514562005083100000) 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-187222-S06063010362005083100000) .

1. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement (6.0L (LQ4))»(ref-187255-S34927328222005083100000) in Engine Mechanical 6.0L.
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 sight shield. Refer to «Engine Sight Shield Replacement (6.0L (LQ4))»(ref-187255-S34927328222005083100000) in Engine Mechanical 6.0L.

1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-187255-S36392058672005083100000) in Engine Mechanical.
2. Remove the knock sensor wiring harness assembly.
3. Remove the knock sensor (KS).

1. Install the knock sensor. Tighten: Torque the sensor to 20 N.m (15 lb ft).
2. Install the knock sensor wiring harness assembly.
3. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-187255-S36392058672005083100000) in Engine Mechanical.

1. Loosen the 2 fasteners securing the air cleaner housing top cover.
2. Lift and rotate the top cover of the air cleaner housing to gain access to the air filter element.
3. Lift 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.
2. Rotate and install the top cover to the air cleaner housing.
3. Insert the fasteners to secure the top cover.

1. Remove the air intake duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-187222-S15189587742005083100000) .
2. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor connector.
3. Loosen the clamp securing the MAF/IAT sensor to the air cleaner assembly.
4. Remove the MAF/IAT sensor.
5. Remove the air cleaner housing fasteners.
6. Remove the air cleaner assembly.

1. Position the air cleaner assembly onto the air cleaner adaptor.
2. Install the fasteners. Tighten: Tighten the air cleaner housing fasteners to 10 N.m (89 lb in).
3. Secure the air cleaner assembly onto the air cleaner adaptor.
4. Install the MAF/IAT sensor to the air cleaner assembly.
5. Secure the clamps at the MAF/IAT sensor and the air cleaner assembly.
6. Connect the MAF/IAT connector.
7. Install the air intake duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-187222-S15189587742005083100000) .

1. Loosen the clamp and separate the air cleaner resonator outlet duct 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.