Engine Controls - Remove/install/overhaul - 2.4l Oldsmobile Achieva I final

INTRODUCTION

This article covers removal, overhaul and installation procedures (when given by manufacturer). If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be supplied.

POWERTRAIN CONTROL MODULE (PCM)

Note. Before replacing PCM, carefully inspect all wiring and control components. Failure to test for short circuits may result in repeated PCM failure due to shorts. To prevent internal damage to PCM, ensure ignition switch is in OFF position when connecting or disconnecting PCM connectors or any electrical components.

Removal & Installation

Turn ignition off. Disconnect negative battery cable. Locate PCM. See PCM LOCATION table. Remove any necessary components to gain access to PCM. Disconnect electrical connectors from PCM. Remove PCM mounting bolts (if equipped). Remove PCM. To install, reverse removal procedure. Transfer any necessary components (i.e., knock module, EEPROM, etc.) to new PCM before installation. Program replacement PCM using appropriate equipment and latest software.

PCM LOCATION

ELECTRICALLY ERASABLE PROGRAMMABLE READ-ONLY MEMORY (EEPROM)

EEPROM is a permanent memory that is part of PCM. EEPROM cannot be replaced. EEPROM contains program and calibration information that PCM uses to control powertrain. If PCM is replaced, ensure NEW PCM software/calibration is correct and most recent version for vehicle. EEPROM must be programmed when NEW PCM is installed. Program EEPROM using latest software for that specific vehicle.

IGNITION CONTROL MODULE (IDI)

Removal

1. Disconnect negative battery cable. Disconnect 11-pin harness connector. Remove 4 IDI cover assembly-to-camshaft housing bolts. Remove ignition system assembly from engine.
2. Remove 4 coil housing-to-cover screws. Remove housing cover. Remove coil harness connector from module. Remove module-to-cover screws. Remove module from cover.

Note. DO NOT wipe grease from module or coil if module is not being replaced. If installing a NEW module, spread silicone grease on metal face of module and on cover where module seats. Grease is included with NEW module and is necessary for module cooling purposes.

Installation

To install, reverse removal procedure. Tighten screws and bolts to specification. See TORQUE SPECIFICATIONS .

Disconnect negative battery cable. Disconnect electrical connector from camshaft position sensor. Remove camshaft position sensor mounting bolt and remove camshaft position sensor. To install, reverse removal procedure. Tighten camshaft position sensor bolt to specification. See TORQUE SPECIFICATIONS .

1. Disconnect negative battery cable. Disconnect electrical connector from crankshaft position sensor. Remove crankshaft position sensor mounting bolt/nut and remove crankshaft position sensor.
2. Inspect crankshaft sensor "O" ring for wear, cracks or other damage. Replace as necessary. Lubricate NEW "O" ring with engine oil before installing. To install, reverse removal procedure. Tighten crankshaft position sensor bolt/nut to specification. See «TORQUE SPECIFICATIONS»(/oldsmobile/achieva/i-final-1998-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-24l__torque-specifications) .

1. Disconnect negative battery cable. Disconnect 11-pin harness connector. Remove 4 IDI cover assembly-to-camshaft housing bolts. Remove ignition system assembly from engine. Remove 4 coil housing-to-cover screws. Remove housing cover.
2. Disconnect coil harness connector from module. Remove ignition coil, contacts and seals from cover. To install, reverse removal procedures. Tighten screws and bolts to specification. See «TORQUE SPECIFICATIONS»(/oldsmobile/achieva/i-final-1998-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-24l__torque-specifications) .

FUEL PRESSURE RELIEF

Fuel system is under pressure. Pressure must be relieved prior to servicing fuel system. Fuel pressure may be relieved by using one of the following methods.

1. Loosen fuel filler cap to relieve tank pressure (do not tighten at this time). Disconnect fuel pump connector. Start and run engine until it stalls. Crank starter for 3 seconds to remove remaining fuel from fuel lines. Turn ignition off. Reconnect fuel pump connector. Disconnect negative battery cable to avoid possible fuel discharge in accidental attempt to start engine.

Removal Procedure (Grand Am, Achieva)

The fuel filter is located under the rear of the car, rearward of the fuel tank. There is no service interval for fuel filter replacement. Replacement is required only if the fuel filter becomes restricted.

Locating Fuel Filter. Scheme 1

1. Remove the negative battery cable.
2. Relieve the fuel system pressure. Refer to «FUEL PRESSURE RELIEF»(/oldsmobile/achieva/i-final-1998-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-24l__fuel-pressure-relief) . CAUTION: Provide additional support when a vehicle is on a hoist in the following ways: Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off. Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off. Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.
3. Raise the vehicle and suitably support.
4. Using a back-up wrench, remove fuel filter fitting. CAUTION: In order to Reduce the Risk of Fire and Personal Injury: If nylon fuel pipes are nicked, scratched or damaged during installation, Do Not attempt to repair the sections of the nylon fuel pipes. Replace them. When installing new fuel pipes, Do Not hammer directly on the fuel harness body clips as it may damage the nylon pipes resulting in a possible fuel leak. Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period. Before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.)
5. Grasp the fuel filter and nylon fuel connection line fitting. Twist quick-connect fitting 1/4 turn in each direction to loosen any dirt within fitting. Using compressed air, blow out dirt from quick-connect fittings at end of fuel filter.
6. Remove the quick connect fitting by pushing inward toward the fuel filter and grasping plastic tab around the connector and pull apart.
7. Remove the fuel filter (1).

Installation Procedure

1. Remove the protective caps from the new filter.
2. Install the filter (1) in same position as the old filter. Apply a few drops of clean engine oil to the male tube end of the filter and of the fuel sender assembly. Push connectors together to cause the retaining tabs/fingers to snap into place. NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Once installed, pull on both ends of each connection to make sure they are secure. Tighten Use back up wrench to prevent filter, O-ring or fuel line damage. Tighten the fitting to 27 Nm (20 lb ft).
3. Install the fuel filter fitting using a new O-ring.
4. Lower the vehicle.
5. Install the fuel filler cap.
6. Install the negative battery cable.
7. Inspect for fuel leaks through the following steps: Turn the ignition switch to the ON position for 2 seconds. Turn the ignition switch to the OFF position for 10 seconds. Turn the ignition switch to the ON position. Check for fuel leaks.

THROTTLE BODY (SFI)

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/oldsmobile/achieva/i-final-1998-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-24l__fuel-pressure-relief) . Disconnect negative battery cable. Remove air intake ducts. Disconnect and mark electrical connections and vacuum hoses from throttle body. Disconnect control cables from throttle body.
2. Drain cooling system and remove coolant hoses to throttle body (if applicable). Remove throttle body retaining bolts. Remove throttle body and gasket.

Note. Identification number is stamped on throttle body. Use identification number to order replacement components.

1. To install, reverse removal procedure using NEW gasket. Tighten throttle body retaining bolts to specification. See «TORQUE SPECIFICATIONS»(/oldsmobile/achieva/i-final-1998-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-24l__torque-specifications) . Refill cooling system (if drained).
2. If installing NEW Idle Air Control (IAC) valve, ensure IAC pintle length setting is adjusted before installation (if applicable). See IDLE AIR CONTROL (IAC) VALVE. Adjust idle speed and TP sensor (if removed, and if adjustable). See ADJUSTMENTS - 2.4L article.

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/oldsmobile/achieva/i-final-1998-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-24l__fuel-pressure-relief) . Disconnect negative battery cable. Remove air cleaner outlet resonator (if necessary). Remove fuel rail bracket (if equipped). Disconnect pressure regulator vacuum hose. Remove fuel return line and "O" ring from pressure regulator. Remove fuel rail. See «FUEL RAIL & INJECTORS»(/oldsmobile/achieva/i-final-1998-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-24l__fuel-rail-injectors) .
2. Remove pressure regulator screws. Remove pressure regulator from fuel rail. Remove pressure regulator retainer and spacer assembly from fuel rail (if equipped). Remove fuel inlet "O" ring from pressure regulator. Remove and discard filter screen if dirty.

To install, reverse removal procedure. DO NOT reuse "O" rings. Lubricate fuel inlet "O" ring with oil and install in regulator. Replace filter screen as necessary. Tighten screws to specification. See TORQUE SPECIFICATIONS .

FUEL RAIL & INJECTORS

Note. If injector is replaced, ensure replacement injector has the same part number as injector removed.

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/oldsmobile/achieva/i-final-1998-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-24l__fuel-pressure-relief). Disconnect negative battery cable. Remove air cleaner outlet duct clamp. Remove air cleaner outlet duct from air cleaner resonator. Loosen air cleaner resonator clamp at throttle body. Remove resonator retaining bolts and nuts. Lift air cleaner resonator from throttle body.
2. Remove crankcase vent hose to bottom of resonator. Remove resonator. Disconnect vacuum hose at pressure regulator. Remove fuel rail attaching bolts. Disconnect camshaft position sensor electrical connector. Push in on injector connector clip and disconnect electrical connectors from injectors.
3. Using a wrench to hold fuel inlet fitting, disconnect and plug fuel inlet line at fuel rail. Lift fuel rail assembly from cylinder head. Loosen fuel return pipe retaining bracket screw. Rotate retaining bracket for removal of fuel return pipe. Remove fuel return pipe from pressure regulator.
4. Remove inlet and return pipe to fuel feed and return line connections. Remove inlet and return pipe assemblies and discard "O" rings. Remove fuel rail assembly. see scheme 3 Remove injector-to-fuel rail retaining clip. Remove injector from fuel rail. Remove injector "O" rings and discard.

Scheme 2

To install, reverse removal procedure. Lubricate NEW injector "O" rings with clean engine oil. Position injectors into fuel rail and install retaining clips. Install NEW injector-to-fuel rail retaining clip with open end facing injector electrical connection. Tighten fuel rail retaining bolts. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

Disconnect electrical connector from IAC valve. Remove IAC valve, gasket and "O" ring from throttle body assembly.

1. Inspect gasket or "O" ring for damage. Replace as necessary. Check extended distance of IAC pintle before installing. Damage will occur if measurement is incorrect. Distance must not exceed 1.100" (28 mm). Measurement should be taken from valve housing flange to end of pintle cone.
2. To retract NEW IAC valve pintle, slowly exert finger pressure on valve. Install NEW "O" ring or gasket on valve. Coat "O" ring with clean engine oil. Install IAC valve. Tighten IAC valve to specification. See «TORQUE SPECIFICATIONS»(/oldsmobile/achieva/i-final-1998-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-24l__torque-specifications) . Reconnect electrical connector to IAC valve. To reset IAC valve, refer to ADJUSTMENTS - 2.4L article.

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/oldsmobile/achieva/i-final-1998-1998/remont/removal-installation/#engine-controls-removeinstalloverhaul-24l__fuel-pressure-relief) . Disconnect negative battery cable. Remove filler neck. Lower fuel tank. Disconnect fuel lines and electrical connection.
2. Remove fuel level sending unit and fuel pump retaining bolts or cam lock ring. Lift assembly from fuel tank and remove fuel pump from sending unit.
3. Pull fuel pump upward while pulling away from bottom support. DO NOT damage rubber insulator and strainer. To install, reverse removal procedure using NEW "O" ring and gasket.

Turn ignition off. Disconnect electrical connector from TP sensor. Remove TP sensor retaining screws. Remove TP sensor from throttle body. With throttle valve in closed position, install TP sensor on throttle body. Ensure TP sensor lever engages with drive lever on throttle shaft. Install retaining screws and electrical connector. TP sensor is self-zeroing and is not adjustable.

OXYGEN SENSOR

Oxygen sensor is mounted in exhaust pipe, below exhaust manifold. It is equipped with a permanent pigtail which must remain intact when removing sensor.

1. Ensure oxygen sensor is free of contaminants. DO NOT use cleaning solvents of any type. Oxygen sensor may be difficult to remove when engine temperature is less than 120°F (48°C). Excessive removal force may damage threads in exhaust manifold or pipe.
2. Disconnect negative battery cable. Disconnect electrical connector from oxygen sensor. Carefully remove oxygen sensor from exhaust pipe.

1. Whenever an oxygen sensor is removed, coat threads with anti-seize compound before installation. New oxygen sensors already have this compound applied to threads.
2. Install oxygen sensor in exhaust pipe. Tighten oxygen sensor to 30 ft. lbs. (41 N.m). Reconnect electrical connector to oxygen sensor. Reconnect negative battery cable.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TORQUE SPECIFICATIONS
• FUEL PRESSURE RELIEF
• FUEL RAIL & INJECTORS