Engine Controls - Removal & Installation: Other Pontiac Aztek I

THROTTLE BODY

1. Partially drain the cooling system. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. see scheme 5 Disconnect the breather tube from the air cleaner intake duct.
2. Remove the air cleaner intake duct. Disconnect the Idle Air Control (IAC) valve electrical connector. (Scheme 12) Disconnect the Throttle Position (TP) sensor electrical connector. Disconnect the accelerator cable cross slug from the throttle body lever. Disconnect the cruise control cable from the throttle lever. Remove the accelerator control cable bracket with accelerator and cruise control cables attached and set aside. Disconnect the throttle body coolant by-pass hoses.
3. Disconnect the heater pipe nut at the throttle body. Remove the nuts and bolts holding the throttle body to the intake manifold. Remove the throttle body assembly.

Cleaning

Clean the throttle body bore and the throttle valve plate using a clean shop towel with GM Top Engine Cleaner, (1052626) or an equivalent product. If the deposits are excessive, disassemble the throttle body for cleaning. After disassembly, clean the throttle body using a parts cleaning brush. DO NOT immerse the throttle body in any cleaning solvent. Assemble the throttle body.

1. Clean the gasket surface on the intake manifold and the throttle body assembly. Install a new gasket, if necessary. Install the throttle body assembly. Install the throttle body retaining nuts and bolts. Tighten the throttle body retaining nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155806-S21244843402003062600000) .
2. Connect the throttle body coolant by-pass hoses. Connect the heater pipe nut at the throttle body. Connect the IAC valve electrical connector. Connect the TP sensor electrical connector.
3. Install the accelerator controls cable bracket. Connect the accelerator cable cross slug to the throttle body lever. Connect the cruise control cable to the throttle body lever. Install the air intake tube and tighten the clamps. Connect the IAT sensor electrical connector.
4. Connect the breather tube to the air intake tube. Refill the cooling system. See «COOLING SYSTEM BLEEDING»(ref-155806-S11086296652003062600000) under COOLING SYSTEM.
5. The throttle should operate freely without binding between full closed and wide open throttle. Inspect for complete throttle opening and closing positions by operating the accelerator pedal. Also inspect for poor carpet fit under the accelerator pedal.

Scheme 12

POWERTRAIN CONTROL MODULE

Note. In order to prevent internal damage to the Powertrain Control Module (PCM), the ignition must be OFF when disconnecting or reconnecting the PCM connector. Service should normally consist of either replacement of the PCM or Electrically Erasable Programmable Read-Only Memory (EEPROM) re-programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first in order to verify the PCM is the correct part. DTC P0602 indicates the EEPROM programming has malfunctioned. When DTC P0602 is set, re-program the EEPROM.

Note. There are no user serviceable parts in this PCM. The PCM should never be opened for any reason. When replacing the production PCM with a service PCM (controller), it is important to transfer the broadcast code and production PCM number to the service PCM label. Do not record this information on the PCM cover. Transfer allows positive identification of PCM parts throughout the service life of the vehicle.

1. PCM is located inside air filter assembly. see scheme 3 Turn ignition off. Disconnect negative battery cable. Remove the engine coolant heater harness from the front fender diagonal brace, if equipped.
2. Reposition the engine coolant reservoir from the front fender diagonal brace. see scheme 2 Reposition the cruise control module from the front fender diagonal brace. Remove the front fender diagonal brace to the inner fender bolt.
3. Remove the front fender diagonal brace to radiator support bolts. Remove the front fender diagonal brace. Remove the air cleaner assembly cover and lift the PCM from the assembly. Disconnect the harness connectors from the PCM. Remove the PCM from the engine compartment.

1. Install the connectors to the PCM. Tighten the PCM connector screws to specification. See «TORQUE SPECIFICATIONS»(ref-155806-S21244843402003062600000) . Install the PCM into the air cleaner assembly.
2. Install the air cleaner assembly cover. Tighten the air cleaner assembly cover retainers. Position the front fender diagonal brace to the radiator support and to the inner fender. Install the bolts to the front fender diagonal brace at the radiator support. Tighten the front fender diagonal brace-to-radiator support bolts to specification.
3. Install the bolts to the front fender diagonal brace at the inner fender. Tighten the front fender diagonal brace-to-the inner fender bolts to specification. Reposition the underhood wiring junction block to the front fender diagonal brace. Connect the negative battery cable.
4. If a new PCM is being installed, program the EEPROM. See «POWERTRAIN CONTROL MODULE»(ref-155806-S16020889862003071500000) under PROGRAMMING.

CRANKSHAFT POSITION SENSOR

Note. For additional diagnostic information, see DTC P0336: CRANKSHAFT POSITION SENSOR CIRCUIT under DIAGNOSTIC TESTS in SELF-DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS article.

1. Install a scan tool.
2. With a scan tool, monitor the powertrain control module for DTCs. If other DTCs are set, except DTC P1336, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-155075-S27919636112003060600000) in SELF-DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS article.
3. With a scan tool, select the crankshaft position variation learn procedure.
4. Observe the fuel cut-off for the engine that you are performing the learn procedure on.
5. The scan tool instructs you to perform the following: Block drive wheels. Apply vehicles parking brake. Cycle ignition from OFF to ON. Apply and hold brake pedal. Start and idle engine. Turn OFF the A/C. Place transmission in Park (A/T) or Neutral (M/T). The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft Position (CKP) sensor activity. If there is a CKP sensor condition, refer to the applicable DTC that set. See «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-155075-S27919636112003060600000) in SELF-DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS article. Camshaft Position (CMP) sensor activity. If there is a CMP sensor condition, refer to the applicable DTC that set. See «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-155075-S27919636112003060600000) in SELF-DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS article. Engine Coolant Temperature (ECT). If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature.
6. With the scan tool, enable the crankshaft position system variation learn procedure.
7. Slowly increase the engine speed to the RPM that you observed.
8. Immediately release throttle when fuel cut-off is reached.
9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, see «DIAGNOSTIC SYSTEM CHECK -- ENGINE CONTROLS»(ref-155075-S24848794192003060600000) under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS article. If a DTC set, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-155075-S27919636112003060600000) in SELF-DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS article.
10. Turn ignition off for 30 seconds after the learn procedure has been completed successfully.

No Driver Information Center

1. With ignition on and engine off, fully push and release the accelerator pedal slowly 3 times within 5 seconds.
2. Turn ignition OFF.
3. If the CHANGE ENGINE OIL message comes back on, the engine oil life monitor has not reset. Repeat the procedure.

Optional Driver Information Center

1. Turn ignition on, with engine off.
2. Press the MODE button until the DIC reads OIL LIFE LEFT/HOLD SET TO RESET.
3. Press and hold the SET button until 100 percent is displayed. You will hear 3 chimes and the CHANGE ENGINE OIL message will go off. If the CHANGE ENGINE OIL message comes back on, the monitor has not reset. Repeat the procedure.

Note. Programming Powertrain Control Module (PCM) requires a compatible scan tool and a Techline(R) terminal. Procedure uses a Tech 2 scanner.

Remote Programming

Note. DO NOT program a control module unless you are directed by a service procedure or you are directed by a technical service bulletin. Programming a control module at any other time will not permanently correct a customer's concern.

Before Programming a Control Module

1. Vehicle system voltage: There is no charging system concern. All charging system concerns must be repaired before programming a control module. Battery voltage is greater than 12 volts but less than 16 volts. The battery must be charged before programming the control module if the battery voltage is low. A battery charger is NOT connected to the vehicle's battery. Incorrect system voltage or voltage fluctuations from a battery charger, may cause programming failure or control module damage. Turn OFF or disable any system that may put a load on the vehicle's battery. Twilight sentinel and Interior lights. Daytime Running Lights (DRL). Applying the parking brake, on most vehicles, disables the DRL system. See owner's manual. Heating, Ventilation, and Air Conditioning (HVAC) systems. Engine cooling fans, etc.
2. The ignition switch is in the proper position. The scan tool prompts you to Turn ignition on, with engine off. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so.
3. All tool connections are secure. RS-232. The connection at the Data Link Connector (DLC) is secure. Voltage supply circuits.
4. DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur.

Remote Programming

1. Turn ignition off
2. Install the Tech 2(tm) to the data link connector (DLC).
3. Turn ignition on, with engine off.
4. Turn OFF all vehicle accessories.
5. With the Tech 2(tm), select Service Programming.
6. Identify vehicle information as requested by the Tech 2(tm).
7. Select the type of module you are programming.
8. Select the type of programming to be performed.
9. Verify the displayed VIN with the vehicle VIN. If the displayed VIN does not match the actual VIN, write down the actual VIN and correct the VIN at the Techline(tm) terminal.
10. When complete, Exit Service Programming.
11. Turn OFF the Tech 2(tm) and disconnect the Tech 2(tm) from the vehicle.
12. Turn ignition off
13. Connect the Tech 2(tm) to the Techline(tm) terminal.
14. Select Service Programming.
15. Select Tech 2(tm) as the tool you are using.
16. Select the type of programming to be performed.
17. Verify the displayed VIN with the vehicle VIN. Correct the VIN as necessary.
18. Select the type of module you are programming.
19. Identify what type of programming that you are performing. Normal. This type of programming is for updating an existing calibration or programming a new controller. Vehicle Configuration Index (VCI). This selection is used if the vehicle VIN is unavailable or not recognized by the Techline(tm) terminal. You will need to contact the Techline(tm) customer support center to use this option. Reconfigure. This is to reconfigure a vehicle, such as tire size and axle ratio changes.
20. Select the appropriate calibration file.
21. Ensure all connections are secure.
22. Select Reprog to initiate the download of the new calibration to the Tech 2(tm).
23. After the download is complete, turn OFF the Tech 2(tm).
24. Disconnect the Tech 2(tm) from the Techline(tm) terminal.
25. Install the Tech 2(tm) to the data link connector (DLC).
26. Turn ON the Tech 2(tm).
27. Turn ignition on, with engine off.
28. Select Service Programming.
29. Select Program.
30. After the download is complete, EXIT Service Programming.
31. Turn ignition off for 30 seconds.
32. Turn OFF the Tech 2(tm).
33. If a control module is replaced the following service procedures must be performed: «CRANKSHAFT POSITION SENSOR»(ref-155806-S03162672562003071500000) «ENGINE OIL LIFE RESET»(ref-155806-S22487557482003071500000) , and «THEFT DETERRENT PASSWORD LEARN PROCEDURE»(ref-155806-S25940539302003071500000) . After the 3 procedures are performed, you must perform «INSPECTION/MAINTENANCE COMPLETE SYSTEM SET PROCEDURE»(ref-155075-S08016051632003060600000) under DRIVE CYCLES in SELF-DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS article.

Programming Verification

1. With a scan tool, clear the DTCs.
2. Attempt to start the engine.
3. Repeat the Service Programming procedure if the engine does not start or operates poorly. Perform the following procedures before programming the PCM: Ensure the control module and DLC connections are okay. Ensure the Techline(tm) operating software is up to date. Ensure the calibration part number is correct for the vehicle.
4. Attempt to program the control module. If the control module still cannot be programmed properly, replace the control module. See «POWERTRAIN CONTROL MODULE»(ref-155806-S12101337522003062600000) under COMPUTERIZED ENGINE CONTROLS. You must program the replacement control module.

Off-Board Programming

Note. DO NOT program a control module unless you are directed by a service procedure or you are directed by a technical service bulletin. Programming a control module at any other time will not permanently correct a customer's concern. The Off-Board Programming is used in situations where a control module must be programmed without having the vehicle present. The Off-Board Programming Adapter must be used to perform the Off-Board Programming procedure. The adapter allows the control module to power up and allows the Tech 2(tm) to communicate with the control module. DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur.

Before Programming a Control Module

1. Ensure that all connections are secure at the following locations: Off-Board Programming Adapter. Tech 2(tm). Control module. Techline(tm) terminal.

Off-Board Programming

1. Obtain the VIN of the vehicle for which the control module is being programmed.
2. With the Techline(tm) terminal, select Service Programming.
3. Select Tech 2(tm), Reprogram ECU, and Off-Board Programming Adapter as the ECU location.
4. Connect the control module, Off-Board Programming Adapter, and the Tech 2(tm) as described on the Techline(tm) terminal. Ensure you use the correct harness connector from the Off-Board Programming Adapter kit.
5. With the Tech 2(tm), select Service Programming Request Information function. The Tech 2(tm) communicates with the control module and receives the access code.
6. With the Tech 2(tm), exit the Service Programming Request Information.
7. Disconnect the Tech 2(tm) from the Off-Board Programming Adapter.
8. Connect the Tech 2(tm) to the Techline(tm) terminal.
9. Turn ON the Tech 2(tm).
10. With the Techline(tm) terminal, enter the VIN of the vehicle that will be receiving the control module.
11. The Techline(tm) terminal will display the message, attaching to database.
12. Identify what type of programming that you are performing.
13. Select the appropriate calibration file.
14. Ensure all connections are secure.
15. The Techline(tm) terminal displays a summary screen that summarizes your selections. After confirming you choices, the Techline(tm) terminal automatically loads the calibration files to the Tech 2(tm).
16. After download is complete, turn OFF the Tech 2(tm).
17. Disconnect the Tech 2(tm) from the Techline(tm) terminal.
18. Connect the Tech 2(tm) to the Off-Board Programming Adapter.
19. With the Tech 2(tm), select Service Programming.
20. With the Tech 2(tm), select Program.
21. After the download is complete, exit Service Programming.
22. Turn OFF the Off-Board Programming Adapter.

Set Up a New Theft Deterrent Control Module

Note. When replacing a theft deterrent control module with an GM Service Parts Operation (SPO) Replacement Part, set up the control module prior to the 10-minute relearn procedure or the 30-minute relearn procedure.

Use this procedure only if replacing the theft deterrent control module with an GM SPO Replacement Part.

1. Connect a scan tool to the vehicle.
2. Turn ignition on, with engine off.
3. With a scan tool, select Setup New VTD Module in the Vehicle Theft Deterrent, Special Functions data list.
4. Follow the scan tool on-screen instructions.

Note. When replacing a theft deterrent control module with an GM SPO Replacement Part, the module will learn the keys immediately. The existing Powertrain Control Module (PCM) must learn the new fuel continue password when you replace the theft deterrent control module. When replacing a PCM with a GM SPO Replacement Part, the new PCM will learn the incoming fuel continue password immediately after programming and upon receipt of a password message. Once a password message is received and a password is learned, perform the learn procedure to change this password again. A PCM which had been installed in another vehicle will have learned the fuel continue password of the other vehicle's theft deterrent control module. Perform either the 10-minute relearn procedure or the 30-minute relearn procedure after programming to learn the fuel continue password of the current vehicle's theft deterrent control modules. When performing either relearn procedure, all previously learned keys will be erased from the theft deterrent control module's memory. Additional keys may be learned immediately after the first relearn procedure by inserting the additional key and turning the ignition to RUN within 10 seconds of removing the previously learned key. Use only a master key when performing the first relearn procedure. If you use a valet key first, the theft deterrent control module will not allow additional keys to be learned.

10-Minute Learn Procedure

Use this procedure after replacing the following components

1. PassKey(R) III (PK3) keys.
2. Theft deterrent control module.
3. PCM.

Note. If replacing a theft deterrent control module with a GM SPO Replacement Part, perform the procedure to setup a new theft deterrent control module prior to the 10-minute relearn procedure.

1. Connect a scan tool to the vehicle.
2. Turn ignition on, with engine off.
3. Ensure that all power consuming devices are turned OFF on the vehicle.
4. With scan tool, select Request Info. under Service Programming System and follow the scan tool on-screen instructions.
5. Disconnect the scan tool from the vehicle and connect the scan tool to a Techline(tm) terminal with the current Service Programming System (SPS) software.
6. On the Techline(tm) terminal, select Service Programming System and follow the Techline(tm) Terminal on-screen instructions.
7. Disconnect the scan tool from the Techline(tm) terminal and re-connect the scan tool to the vehicle.
8. With a master PassKey(R) III key, turn ignition on, with engine off.
9. With a scan tool, select Program ECU under Service Programming System.
10. At this point the scan tool must remain connected for the duration of the 10-minute relearn procedure.
11. Observe the scan tool, after approximately 10 minutes the scan tool will display "Programming Successful, Turn OFF Ignition". The vehicle is now ready to relearn the key information and/or the passwords on the next ignition switch transition from OFF to ON.
12. Turn ignition off and wait 5 seconds.
13. With a master PassKey(R) III key, start the vehicle. The theft deterrent control module has now learned the key transponder information and the PCM has now learned the fuel continue password.
14. Turn ignition off and wait 15 seconds minimum.
15. With a second master PassKey(R) III key, start the vehicle. The theft deterrent control module has now learned the second master PassKey(R) III key transponder information.
16. With a scan tool, clear any DTCs.

30-Minute Learn Procedure

Use this procedure after replacing the following components

1. PassKey(R) III (PK3) keys.
2. Theft deterrent control module.
3. PCM.

Note. This procedure is not available on vehicles equipped with option code (Z49 or BAE). If replacing a theft deterrent control module with an GM SPO Replacement Part, perform the procedure to setup a new theft deterrent control module prior to the 30-minute relearn procedure.

1. With a master PassKey(R) III key (Black), Turn ignition on, with engine off.
2. Observe the Security telltale, after about 10 minutes, the telltale will turn off.
3. Turn ignition off and wait 5 seconds.
4. Repeat steps 1 - 3 for 2 more times, for a total of 3 cycles or 30 minutes.
5. With a master PassKey(R) III key, start engine. The vehicle has now learned the key transponder information and the PCM has now learned the fuel continue password.
6. With a scan tool, clear any DTCs.

Turn ignition off. Remove the power steering pump. See appropriate POWER RACK & PINION article in STEERING. Disconnect the Camshaft Position (CMP) sensor electrical connector. (Scheme 13) Remove the attaching bolt. Remove the CMP sensor. Inspect the sensor "O" ring for wear, cracks, or leakage if the sensor is not being replaced.

Replace the "O" ring if the "O" ring is damaged. Lubricate the "O" ring with clean engine oil. Install the CMP sensor. Tighten the CMP sensor retaining bolt to specification. See TORQUE SPECIFICATIONS . Connect the CMP sensor electrical connector. Install the power steering pump. Tighten power steering pump mounting bolts to specification.

Scheme 13

1. The Crankshaft Position (CKP) sensor is located behind the crankshaft balancer. (Scheme 14) Turn the ignition off. Remove the drive belt. Raise and support the vehicle.
2. Remove the right front tire and wheel. Remove the right engine splash shield. Install a utility stand beneath the frame right side rail in order to support the frame/powertrain. Remove the two frame right side bolts. Use the utility stand to lower the frame enough to provide access to the crankshaft balancer.
3. Remove and discard the crankshaft balancer bolt. Using Crankshaft Balancer Puller (J-24420-C), remove the crankshaft balancer. Note the routing of the CKP sensor harness before removal. Remove the harness retaining clip and bolt. Disconnect the CKP sensor electrical connector. Remove the sensor bolts. Remove the CKP sensor.

1. Install the 24X CKP sensor with bolts and the route harness as noted during removal. Install the harness retaining clip and bolt. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155806-S21244843402003062600000) .
2. Connect the CKP sensor electrical connector. Apply Sealer (12345739) or the equivalent to the keyway of the crankshaft balancer. Install the crankshaft balancer into position over the key in the crankshaft. Using Crankshaft Balancer Installer (J-29113), install the crankshaft balancer to the crankshaft.
3. Remove the crankshaft balancer installer from the crankshaft balancer. Install the crankshaft balancer washer and the NEW crankshaft balancer bolt. Tighten the bolt to specification. Use the utility stand in order to raise the frame/powertrain. Install the frame right side bolts. Tighten frame bolts to specification.
4. Install the engine splash shield. Install the right front tire and wheel. Tighten wheel lug nuts to specification. Lower the vehicle. Install the drive belt. Perform the CKP System Variation Learn Procedure. See «CRANKSHAFT POSITION SENSOR»(ref-155806-S03162672562003071500000) under PROGRAMMING.

Scheme 14

1. The Crankshaft Position (CKP) sensor is mounted in cylinder block. (Scheme 15) Turn the ignition off. Raise and support the vehicle.
2. On front-wheel drive vehicles, remove the right front tire and wheel. On all-wheel-drive vehicles, disconnect the catalytic converter from the exhaust manifold and reposition.
3. On all models, disconnect the CKP sensor electrical connector. Remove the CKP sensor attaching bolt. Remove the CKP sensor from the engine. Inspect for wear, cracks, or leakage if the sensor is not being replaced.

1. Replace the "O" ring, if it is damaged. Lubricate the "O" ring with clean engine oil. Install the sensor to the block. Install the CKP sensor attaching bolt. Tighten the bolt to specification. See «TORQUE SPECIFICATIONS»(ref-155806-S21244843402003062600000) .
2. Install the CKP sensor electrical connector. On front-wheel-drive vehicles, install the right tire and wheel. Tighten wheel lug nuts to specification. On all-wheel-drive vehicles, install the catalytic converter to the exhaust manifold. Tighten catalytic converter to the exhaust manifold nuts to specification. On all models, lower the vehicle.
3. Perform the CKP System Variation Learn Procedure. See «CRANKSHAFT POSITION SENSOR»(ref-155806-S03162672562003071500000) under PROGRAMMING.

Scheme 15

ENGINE COOLANT TEMPERATURE SENSOR

Note. Recover and store used coolant in a used coolant holding tank and submit the used coolant for recycling on a regular basis. Do not pour used coolant down the drain. Ethylene glycol antifreeze is very toxic. Disposing of ethylene glycol into the sewer system or ground water is both illegal and ecologically unsound.

Turn ignition off. Drain the cooling system to below the Engine Coolant Temperature (ECT) sensor. (Scheme 16) Disconnect the ECT sensor electrical connector. Carefully remove the ECT sensor.

Scheme 16

Note. Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.

Coat the ECT sensor threads with Thread Sealer (9985253) or the equivalent. Install the ECT sensor. Tighten the ECT sensor to specification. See TORQUE SPECIFICATIONS . Connect the ECT sensor electrical connector. Refill the engine coolant system. See COOLING SYSTEM BLEEDING under COOLING SYSTEM.

1. Remove fuel sender assembly. See «FUEL SENDER ASSEMBLY»(ref-155806-S23836005462003062600000). Disconnect the fuel pump electrical connector. (Scheme 17)
2. Remove the fuel level sensor electrical connector retaining clip. Disconnect the fuel level sensor electrical connector from under the fuel sender cover. Remove the fuel level sensor retaining clip. Squeeze the locking tangs and remove the fuel level sensor from the fuel sender assembly.

Install the fuel level sensor to the fuel sender assembly. Install the fuel level sensor retaining clip. Connect the fuel level sensor electrical connector. Install the fuel level sensor electrical connector retaining clip. Connect the fuel pump electrical connector. Install the fuel sender assembly. Perform the following procedure in order to inspect for leaks. Turn the ignition on for 2 seconds. Turn the ignition off for 10 seconds. Turn the ignition on. Inspect for fuel leaks.

Scheme 17

Remove the fuel tank. See FUEL TANK. Disconnect the electrical connector from the fuel tank pressure sensor. Remove the fuel tank pressure sensor from the fuel sender assembly. (Scheme 17) To install, reverse removal procedure.

HEATED OXYGEN SENSOR

Note. The oxygen sensor may be difficult to remove when the engine temperature is less than 120°F (48°C). Downstream HO2S may also be referred to as HO2S 2. Upstream HO2S may also be referred to as HO2S 1.

Locate HO2S to be removed. (Scheme 18)or (Scheme 19). Turn ignition off. On HO2S 1, disconnect the electrical connector. On all applications, raise and support vehicle. On HO2S 2 disconnect the electrical connector. Using Oxygen Sensor Wrench (J-39194-B), remove appropriate HO2S.

1. A special anti-seize compound is used on the oxygen sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New sensors will have the compound applied to the threads.
2. If a sensor is removed and is to be reinstalled, the threads must have an anti-seize compound applied before installation. Coat the threads of the HO2S with Anti-Seize Compound (5613695), if necessary.
3. Using Oxygen Sensor Wrench (J-39194-B), install the appropriate HO2S and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-155806-S21244843402003062600000) . On HO2S 2, connect harness connector. On all applications, lower vehicle. On HO2S 1, connect harness connector.

Scheme 18

Scheme 19

The Intake Air Temperature (IAT) sensor is located in the air cleaner intake duct. see scheme 5 Disconnect the IAT sensor electrical connector. Carefully grasp the sensor and with a twisting and pulling motion, and remove the IAT sensor from air intake duct. Install the IAT sensor by snapping into place. Connect the IAT sensor electrical connector.

Turn the ignition off. Raise and support the vehicle. Disconnect the wiring harness connector from the knock sensor. (Scheme 20) Remove the knock sensor from the engine block.

Note. Do not apply thread sealant to the sensor threads. The sensor threads are coated at the factory and applying additional sealant affects the sensor's ability to detect detonation.

Install the knock sensor into the engine block. Tighten the knock sensor to specification. See TORQUE SPECIFICATIONS . Connect the knock sensor wiring harness connector to the knock sensor. Lower the vehicle.

Scheme 20

Turn ignition off. Remove the screws that attach the Manifold Absolute Pressure (MAP) sensor to the bracket. (Scheme 21) Disconnect the MAP sensor electrical connector. Disconnect the MAP inlet vacuum hose. Remove the MAP sensor from the bracket.

Position the MAP sensor to the bracket. Connect the MAP inlet vacuum hose. Connect the MAP sensor electrical connector. Install the MAP sensor screws and tighten to specification. See TORQUE SPECIFICATIONS .

Scheme 21

The Mass Airflow (MAF) sensor is mounted to the air filter housing. see scheme 5 Turn ignition off. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. Disconnect the of the MAF sensor electrical connector. Loosen the air inlet duct clamp from the MAF sensor. Loosen the MAF sensor clamp from the air filter housing. Remove the air inlet duct from the MAF sensor and the throttle body. Remove the MAF sensor from the air filter housing.

Install the MAF sensor to the air filter housing. Install the air inlet duct to the MAF sensor and the throttle body. Tighten clamps. Connect the IAT sensor electrical connector. Connect the MAF sensor electrical connector. Start and idle the engine. Inspect the air intake duct for leaks.

1. Turn the ignition off. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-155806-S16074202252003062600000) under FUEL SYSTEMS. Remove the air cleaner intake duct. See «AIR CLEANER INTAKE DUCT»(ref-155806-S21744190612003070700000) under AIR INDUCTION SYSTEMS. Disconnect the EVAP purge line. (Scheme 22) Disconnect the fuel lines. See «FUEL LINE DISCONNECT FITTINGS»(ref-155806-S18267258292003062600000) under FUEL SYSTEMS.
2. Disconnect the Throttle Position (TP) sensor electrical connector. (Scheme 12) Remove the 2 TP sensor bolts. Remove the TP sensor and "O" ring.

1. Install the TP sensor "O" ring on the TP sensor. Install the TP sensor on the throttle body assembly. Install the 2 TP sensor bolts, using Loctite(R) 262 Thread-Locking Compound (1052624), or equivalent on the bolts.
2. Tighten the TP sensor attaching bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155806-S21244843402003062600000) . Connect the TP sensor electrical connector. Connect the EVAP purge line. Connect the fuel lines. Install the air cleaner intake duct.
3. Perform the following procedure in order to inspect for leaks. Turn the ignition on for 2 seconds. Turn the ignition off for 10 seconds. Turn the ignition on. Inspect for fuel leaks.

Scheme 22

COOLING SYSTEM BLEEDING

Note. Recover and store used coolant in a used coolant holding tank and submit the used coolant for recycling on a regular basis. Do not pour used coolant down the drain. Ethylene glycol antifreeze is very toxic. Disposing of ethylene glycol into the sewer system or ground water is both illegal and ecologically unsound.

1. Ensure the radiator drain cock is closed. Remove the radiator cap. Open the air bleed valve on the thermostat housing 2 full turns. Open the air bleed valve above the water pump 2 full turns. Slowly add a 50/50 mixture of GM Goodwrench Dex-Cool(R) or Havoline(R) Dex-Cool(R) and clean, drinkable water to the radiator until the coolant level is at the base of the radiator fill neck.
2. Wait for 2 minutes and reinspect the level of the coolant in the radiator. If necessary, add coolant to the radiator until the coolant level is at the base of the radiator fill neck. Install the radiator cap. Ensure that the radiator cap arrow points toward the radiator overflow tube.
3. Close the air bleed valves above the coolant pump and the thermostat housing. The air bleed valves are brass. Do not over-tighten the air bleed valves. Fill the coolant reservoir with a 50/50 mixture of GM Goodwrench Dex-Cool(R) Or Havoline(R) Dex-Cool(R) and clean, drinkable water.
4. Start the engine and allow the engine cooling fan to cycle on and off 3 times. Turn off the ignition. Allow the engine to cool. Ensure that the engine coolant concentration is sufficient. Top off coolant reservoir, if necessary.

EVAP CANISTER PURGE SOLENOID

Note. EVAP canister purge solenoid may also be referred to as EVAP canister purge valve or EVAP canister purge solenoid valve.

Turn ignition off. Disconnect the EVAP canister purge solenoid electrical connector. (Scheme 22) Disconnect the EVAP canister purge pipe from the EVAP canister purge solenoid. Disconnect the vacuum supply hose from the EVAP canister purge solenoid. Remove the EVAP canister purge solenoid retaining bolt. Remove the EVAP canister purge solenoid from the intake manifold.

Position the EVAP canister purge solenoid on the intake manifold and install the retainer bolt. Tighten the EVAP canister purge solenoid retaining bolt to specification. See TORQUE SPECIFICATIONS . Connect the EVAP canister purge pipe and the vacuum supply hose. Connect the EVAP canister purge valve electrical connector.

EVAP CANISTER VENT SOLENOID

Note. The EVAP canister vent solenoid may also be referred to as a EVAP canister vent valve or EVAP canister vent solenoid valve.

The EVAP canister vent valve is mounted to the fuel tank. (Scheme 23) Remove the fuel tank. See FUEL TANK under FUEL SYSTEMS. Disconnect the EVAP canister vent solenoid harness connector. Remove the EVAP vent hose from EVAP canister vent solenoid. Bend the EVAP canister vent bracket tab to release the EVAP canister vent solenoid. Remove the EVAP canister vent solenoid from the fuel tank.

Slide the EVAP canister vent solenoid on the EVAP canister vent bracket until the solenoid snaps into place. Connect the EVAP vent hose to the EVAP canister vent solenoid. Connect the EVAP canister vent solenoid harness connector. Install the fuel tank.

Scheme 23

Remove the accelerator control cable bracket from the throttle body. See ACCELERATOR CONTROLS CABLE BRACKET under MISCELLANEOUS. Remove the canister purge valve. Disconnect the Idle Air Control (IAC) valve electrical connector. (Scheme 12) Remove the IAC valve attaching screws. Remove the IAC valve. Remove the IAC valve "O" ring.

1. Measure the distance between the tip of the IAC valve pintle and the mounting surface. (Scheme 24) If the distance is more than 1.10" (28 mm), use finger pressure in order to slowly retract the pintle. The force required to retract the pintle of a new valve will not cause damage to the valve.
2. Lubricate the new IAC valve "O" ring with clean engine oil. Install the IAC valve "O" ring on the IAC valve. Install the IAC valve. Install the IAC valve attaching screws and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-155806-S21244843402003062600000). Connect the IAC valve electrical connector.
3. Install the EVAP canister purge valve. Install the throttle control cable bracket. The PCM will reset the IAC valve whenever the ignition is turned on, then off. Turn the ignition on, then off. Start the engine and allow the engine to reach operating temperature.

Scheme 24

FUEL SYSTEMS

FUEL SYSTEM PRESSURE RELEASE

Turn ignition off. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. Install Fuel Pressure Gauge Adaptor (J-34730-262) to the fuel pressure connection on the fuel rail. Connect Fuel Pressure Gauge (J-34730-1A) to the fuel pressure connection. Wrap a shop towel around the fuel pressure connection while connecting the fuel pressure gauge in order to avoid spillage. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing. Drain any fuel remaining in the fuel pressure gauge into an approved container. Remove the fuel pressure gauge and adaptor.

FUEL FILTER

Note. There is not any service interval for in-pipe fuel filter replacement. Only replace the in-line fuel filter if the filter is restricted. Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages. Always maintain cleanliness when servicing fuel system components. Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware. Do not repair sections of fuel pipes.

1. Fuel filter is located underneath rear of vehicle. (Scheme 25) Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-155806-S16074202252003062600000).
2. Raise and support vehicle. Remove the quick-connect fitting at the inlet of the in-pipe fuel filter. See «FUEL LINE DISCONNECT FITTINGS»(ref-155806-S18267258292003062600000). Drain any remaining fuel into an approved gasoline container.
3. Remove the in-pipe fuel filter mounting bracket nut from stud. Remove the quick-connect fitting at the outlet of the in-pipe fuel filter. Remove the fuel filter from the fuel filter mounting bracket. To install, reverse removal procedure.
4. Perform the following procedure in order to inspect for leaks. Turn the ignition on for 2 seconds. Turn the ignition off for 10 seconds. Turn the ignition on. Inspect for fuel leaks.

Scheme 25

See FUEL LEVEL SENSOR under SENSORS.

1. The fuel pressure regulator is located on end of fuel rail. (Scheme 26) Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-155806-S16074202252003062600000).
2. Disconnect the fuel pressure regulator vacuum line. Remove the fuel pressure regulator retaining screw. Using a shop towel to catch any spilled fuel, lift and twist the fuel pressure regulator in order to remove the fuel pressure regulator from the fuel rail.
3. Remove the retainer and spacer bracket from the rail and discard. Remove the fuel pressure regulator from the engine fuel return pipe. Remove the fuel pressure regulator inlet "O" ring and discard.

1. Check the filter screen for contamination. If contaminated, replace the fuel pressure regulator. Lubricate the new pressure regulator inlet "O" ring with clean engine oil and install on the regulator inlet. Install the fuel return pipe to the regulator.
2. Install the new retainer and spacer bracket into the slot on the fuel rail. Install the pressure regulator to the fuel rail. Tighten the engine fuel return pipe nut to specification. See «TORQUE SPECIFICATIONS»(ref-155806-S21244843402003062600000) .
3. Connect the fuel pressure regulator vacuum line. Install the pressure regulator attaching screw. Tighten the pressure regulator attaching screw to specification. Inspect and verify that the retainer and spacer bracket is engaged in the slots in the fuel rail.
4. Grasp and pull on the regulator to ensure that the regulator is properly seated. Perform the following procedure in order to inspect for leaks. Turn the ignition on for 2 seconds. Turn the ignition off for 10 seconds. Turn the ignition on. Inspect for fuel leaks.

Scheme 26

The fuel pump is attached to the fuel sender assembly inside the fuel tank. See FUEL SENDER ASSEMBLY for removal and installation.

FUEL RAIL & INJECTORS

Note. An 8-digit identification number is located on the fuel rail assembly. Refer to this model identification number if servicing or part replacement is required. Fuel injector "O" rings should always be replaced whenever the fuel injectors are serviced.

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-155806-S16074202252003062600000). Remove the upper intake manifold. See appropriate article in ENGINES. Disconnect the engine fuel feed pipe at the fuel rail. See «FUEL LINE DISCONNECT FITTINGS»(ref-155806-S18267258292003062600000).
2. Disconnect the engine fuel return pipe at the fuel pressure regulator. Remove the fuel feed pipe and fuel return pipe "O" rings and discard. Disconnect the main injector harness electrical connector. To disconnect fuel injector connector, pull up the lock release of the fuel injector connector. Depress the lock tab and lift the connector from the injector. Disconnect all remaining fuel injector connectors.
3. Remove the injector electrical harness from the fuel rail. Disconnect the engine coolant temperature sensor electrical connector. Remove the fuel rail retaining bolts. (Scheme 27) Remove the fuel rail assembly. Remove the injector "O" ring seal from the spray tip end of each injector. Discard the lower "O" ring seals. (Scheme 28)
4. To remove injector(s) from the fuel rail, remove the fuel injector retainer clip. Discard retaining clip. Remove the fuel injector from the fuel rail. Remove and discard the fuel injector upper "O" ring.

1. Lubricate the new injector upper "O" ring seal with clean engine oil. Install the new injector "O" ring seal on the injector. Install a new retainer clip on the injector. Push the fuel injector into the fuel rail injector socket with the electrical connector facing outward. The retainer clip locks on to a flange on the fuel rail injector socket.
2. Install the fuel rail assembly into the intake manifold. Tilt the rail assembly to install the injectors. Install the fuel rail attaching bolts. Tighten the fuel rail attaching bolt to specification. See «TORQUE SPECIFICATIONS»(ref-155806-S21244843402003062600000) .
3. Connect the engine coolant temperature sensor electrical connector. Install the injector electrical harness to the fuel rail. Connect the fuel injector connectors. Push the slide locks into position. Connect the main injector harness electrical connector. Install the new "O" rings on the fuel feed pipe and fuel return pipe.
4. Connect the fuel feed pipe at the fuel rail. Tighten the fuel feed pipe nut to specification. Connect the fuel return pipe at the fuel pressure regulator. Tighten the fuel return pipe nut to specification. Install the upper intake manifold. See appropriate article in ENGINES. Connect the negative battery cable.
5. Perform the following procedure in order to inspect for leaks. Turn the ignition on for 2 seconds. Turn the ignition off for 10 seconds. Turn the ignition on. Inspect for fuel leaks.

Scheme 27

Scheme 28

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-155806-S16074202252003062600000) . Remove the fuel tank. See «FUEL TANK»(ref-155806-S13611800892003062600000) . Remove the fuel sender shield nuts. Remove the fuel sender shield. Disconnect the fuel sender electrical connectors.
2. Disconnect the fuel pipes from the fuel sender. See «FUEL LINE DISCONNECT FITTINGS»(ref-155806-S18267258292003062600000) . Using Fuel Sender Lock Ring Tool (J-39765-A 1), remove the fuel sender lock ring. The fuel sender assembly will spring up when the fuel sender assembly lock ring is removed.
3. The fuel sender must be tipped in order to remove the sender from the fuel tank. Remove the fuel sender from the fuel tank. Remove and discard the fuel sender seal.

1. Clean the fuel sender sealing flange. Install the NEW fuel sender seal to the fuel tank. Do not fold over or twist the fuel pump strainer when installing the fuel sender assembly, as this will restrict fuel flow. Also, ensure that the fuel pump strainer does not block full travel of float arm.
2. Install the fuel sender and the fuel sender lock ring. Use the Fuel Sender Lock Ring Tool (J-39765-A1) in order to install the fuel sender lock ring. Install the fuel pipes to the fuel sender. Install the fuel sender sensor electrical connectors. Install the fuel sender shield.
3. Install the fuel sender shield nuts. Tighten the nuts to specification. See «TORQUE SPECIFICATIONS»(ref-155806-S21244843402003062600000) . Install the fuel tank.
4. Lower the vehicle. Add fuel and reinstall the fuel tank filler pipe cap. Connect the negative battery cable. Perform the following procedure in order to inspect for leaks: Turn the ignition on for 2 seconds. Turn the ignition off for 10 seconds. Turn the ignition on. Inspect for fuel leaks.

FUEL SYSTEM CLEANING

Note. When flushing the fuel tanks, handle the fuel and water mixture as a hazardous material. Handle the fuel and water mixture in accordance with all applicable local, state, and federal laws and regulations. Whenever the fuel tank is cleaned, the fuel pump fuel strainer must be inspected. If the fuel pump fuel strainer is contaminated, the fuel pump fuel strainer must be replaced and the fuel pump must be inspected.

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-155806-S16074202252003062600000) . Drain the fuel tank. See «FUEL TANK DRAINING»(ref-155806-S34805436442003062600000) .
2. Remove the fuel tank. See «FUEL TANK»(ref-155806-S13611800892003062600000) . Remove the fuel sender assembly. See «FUEL SENDER ASSEMBLY»(ref-155806-S23836005462003062600000) .
3. Inspect the fuel pump inlet for dirt and debris. If dirt and debris are found, the fuel pump needs to be replaced. Flush the fuel tank with hot water. Pour the water out of the fuel sender assembly opening in the fuel tank. Rock the fuel tank in order to be sure that the removal of the water from the fuel tank is complete.
4. Allow the tank to dry completely before reassembly. Install the fuel sender assembly. See «FUEL SENDER ASSEMBLY»(ref-155806-S23836005462003062600000) . Install the fuel tank. See «FUEL TANK»(ref-155806-S13611800892003062600000) .
5. Refill the fuel system. Install the fuel filler cap. Connect the negative battery cable. Perform the following procedure in order to inspect for leaks: Turn the ignition on for 2 seconds. Turn the ignition off for 10 seconds. Turn the ignition on. Inspect for fuel leaks.

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-155806-S16074202252003062600000). Drain the fuel tank. See «FUEL TANK DRAINING»(ref-155806-S34805436442003062600000). Raise and support vehicle.
2. Disconnect the fuel tank wiring harness connector at the body pass through. (Scheme 29) Disconnect the quick-connect fittings at the fuel filter. (Scheme 25) See «FUEL LINE DISCONNECT FITTINGS»(ref-155806-S18267258292003062600000).
3. Disconnect the fuel tank EVAP pipe quick-connect fitting near the fuel filter. Remove the fuel feed, the fuel return, and the EVAP lines from the fuel pipe retainer. Remove the retaining nut for the EVAP canister bracket. Loosen the fuel tank filler pipe hose clamp at the fuel tank.
4. Disconnect the fuel tank filler pipe from the fuel tank. Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps. With the aid of an assistant, support the fuel tank and remove the fuel tank strap attaching bolts. Remove the fuel tank from the vehicle.

Scheme 29

Note. When replacing the fuel system hose clamps, always replace the clamps with the original equipment or parts that meet the GM specifications for those parts.

1. With the aid of an assistant, position and support the fuel tank. Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps. Install the fuel tank retaining strap attaching bolts. Tighten the fuel tank retaining strap bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155806-S21244843402003062600000) .
2. Install the EVAP canister retaining nut. Tighten the EVAP canister retaining nut to specification. Connect the fuel tank filler pipe to the fuel tank. Tighten the fuel tank filler pipe hose clamp to specification. Connect the fuel pipe quick-connect fittings at the fuel filter. Connect the fuel tank EVAP pipe quick-connect fitting near the fuel filter.
3. Connect the fuel tank wiring harness connector at the body pass-through. Lower the vehicle. Add fuel and reinstall the fuel tank filler pipe cap. Connect the negative battery cable. Perform the following procedure in order to inspect for leaks: Turn the ignition on for 2 seconds. Turn the ignition off for 10 seconds. Turn the ignition on. Inspect for fuel leaks.

FUEL TANK PRESSURE SENSOR

See FUEL TANK PRESSURE SENSOR under SENSORS.

IDLE AIR CONTROL VALVE

See IDLE AIR CONTROL VALVE under MOTORS & SOLENOIDS.

See THROTTLE BODY under AIR INDUCTION SYSTEMS.

CAMSHAFT POSITION SENSOR

See CAMSHAFT POSITION SENSOR under SENSORS.

CRANKSHAFT POSITION SENSORS

See CRANKSHAFT POSITION SENSOR "A" (24X) or CRANKSHAFT POSITION SENSOR "B" (7X) under SENSORS.

1. Turn ignition off. Disconnect the spark plug wires from the ignition coils. Note the position from which the wires are removed. Remove the 2 screws that secure the ignition coil to the ignition control module. Remove the ignition coil.
2. To install, reverse removal procedure. Tighten the coil screws to specification. See «TORQUE SPECIFICATIONS»(ref-155806-S21244843402003062600000). Connect the spark plug wires to the ignition coils. (Scheme 30)

Scheme 30

1. Disconnect all the electrical connectors at the Ignition Control Module (ICM). Note the position of the spark plug wires for installation and disconnect the spark plug wires from the ignition coils. Remove the screws securing the coil assemblies to the ignition control module.
2. Disconnect the coils from the ignition control module. Remove the fasteners securing the ignition control module assembly to the engine. Remove the ignition control module from the bracket.
3. To install, reverse removal procedure. Tighten the ignition control module screws to specification. See «TORQUE SPECIFICATIONS»(ref-155806-S21244843402003062600000). Connect the spark plug wires to the ignition coils. (Scheme 30)

KNOCK SENSOR

See KNOCK SENSOR under SENSORS.

1. Turn ignition off. To remove spark plugs from left cylinder bank (front cylinder head), remove the spark plug wires from spark plugs. Remove spark plugs from engine. To remove spark plugs from the right cylinder bank (rear cylinder head), remove the throttle air cleaner intake duct. See «AIR CLEANER INTAKE DUCT»(ref-155806-S21744190612003070700000) under AIR INDUCTION SYSTEMS.
2. Set the park brake. Shift the transaxle into Neutral. Remove the engine mount strut bolts. (Scheme 31) Swing the engine mount struts aside. Install the Engine Tilter Strap (J-41131) to the engine. (Scheme 32)
3. Pull on the engine in order to rotate the engine forward. Tighten the engine tilter strap. Remove the spark plug wires from the spark plugs. Remove the spark plugs from the engine.

Scheme 31

Scheme 32

EGR SYSTEM CLEANING

1. Turn the ignition off. Remove Exhaust Gas Recirculation (EGR) valve pipe. See «EGR VALVE PIPE»(ref-155806-S33995449012003062600000) . Clean and inspect the EGR pipe from the exhaust manifold to the EGR valve. Remove the EGR valve. See «EGR VALVE»(ref-155806-S18157771852003062600000) .
2. While holding the EGR valve base in your hand, try to rotate the connector housing. Replace the valve that exhibits looseness. Inspect the EGR valve pintle and seat for deposits. Use a cloth or other suitable soft device to remove deposits. Remove all loose particles.
3. If deposits are such that pintle and/or base interface cannot be cleaned adequately to allow the pintle to seal against the seat, replace the valve. Damage to the EGR valve base will occur if cleaned with solvents, sharp tools, wire brush, wheel or sand blasting. Cleaning by these methods is not recommended. Install the EGR valve on the engine using a new gasket. Install the EGR valve pipe.

EGR VALVE

Note. Whenever the Exhaust Gas Recirculation (EGR) valve is removed, the EGR system should be inspected and cleaned if needed. This will ensure that the EGR system will function properly under all operating conditions. See EGR SYSTEM CLEANING .

1. Disconnect the EGR valve electrical connector. (Scheme 33) Remove the air cleaner assembly. See «AIR CLEANER ASSEMBLY»(ref-155806-S29615517482003070700000) under AIR INDUCTION SYSTEMS. Remove the transaxle fluid filler tube. Remove the bolt retaining the pipe assembly from the EGR valve and carefully pull the pipe assembly back.
2. Remove the EGR valve retaining bolts. Remove the EGR valve assembly. Remove the gasket. Clean the EGR valve mating surface.

Scheme 33

Install the EGR valve with a new gasket to the intake manifold. Install the bolts through the EGR valve. Tighten the bolts to specification. See TORQUE SPECIFICATIONS . Connect the pipe assembly to the EGR valve. Install the transaxle fluid filler tube. Tighten transaxle fluid filler tube bolt/nut to specifications. Install air cleaner assembly. Connect the EGR valve electrical connector.

1. Turn the ignition off. Apply the parking brake. Raise the front of the vehicle approximately 4" (100 mm) with a floor jack. Remove the two front frame bolts. Do not lower the frame and powertrain more than 4" (100 mm) Slowly lower the frame and powertrain approximately 4" (100 mm) from the underbody rails in order to gain access to the EGR pipe.
2. Place two jack stands beneath the frame to prevent any movement of the frame and powertrain assembly. Remove the EGR pipe bolt and the EGR pipe from the EGR valve. (Scheme 34) Loosen the EGR pipe nut in order to remove the EGR pipe from the exhaust manifold. Remove the EGR pipe.

Scheme 34

1. Install the EGR pipe to the exhaust manifold. Tighten the EGR pipe nut to specification. See «TORQUE SPECIFICATIONS»(ref-155806-S21244843402003062600000) . Install the EGR pipe and the EGR pipe bolt to the EGR valve. Tighten the EGR pipe bolt to specification.
2. Use the floor jack in order to raise the frame and powertrain until the frame contacts the underbody rails. Install the frame bolts and tighten bolts to specification. Remove the jack stands. Lower and remove the floor jack. Release the parking brake.

EVAP CANISTER

Note. The EVAP canister may have released carbon particles which caused this part to fail and may cause damage to other components. Check the EVAP canister for loose carbon before returning the vehicle to service.

EVAP canister is mounted to the fuel tank. (Scheme 23) Remove the fuel tank. See FUEL TANK under FUEL SYSTEMS. Remove the 2 retaining nuts connecting the EVAP canister bracket to the fuel tank. Reposition the EVAP canister and disconnect the EVAP system hoses/pipes from the EVAP canister. Remove the EVAP canister from the EVAP canister bracket. To install, reverse removal procedure.

See EVAP CANISTER PURGE SOLENOID under MOTORS & SOLENOIDS.

See EVAP CANISTER VENT SOLENOID under MOTORS & SOLENOIDS.

1. Remove the accelerator cable shield, if equipped. Disconnect the accelerator cable from the throttle body lever. Disconnect the accelerator cable from the accelerator cable bracket.
2. Remove the push-in retainers from the Insulator Panel (IP) insulator to instrument panel. Remove the press-on retainers from the IP insulator to dash mat. Unsnap the IP courtesy lamp from the IP insulator. Remove the IP insulator from the instrument panel.
3. Disconnect the accelerator cable from the accelerator pedal. Squeeze the accelerator cable cover tangs and push the accelerator cable through the bulkhead. Remove the accelerator cable from the vehicle. Note the cable routing for aid in installation. (Scheme 35)

1. Install the accelerator cable into the vehicle using the routing noted during removal. Install the snap retainer through the bulkhead. Connect the accelerator cable through the slot in the accelerator pedal lever. Seat the snap retainer in the accelerator pedal lever.
2. Connect the accelerator cable to the throttle body lever. Connect the accelerator cable to the accelerator cable bracket. Reinstall the accelerator cable shield, if equipped.
3. Inspect and check for complete throttle opening and closing positions by operating the accelerator pedal. Also check for poor carpet fit under the accelerator pedal. Reinstall the left IP insulator.

Scheme 35

1. Disconnect the accelerator controls cable cross slug from the throttle body lever. (Scheme 36) Disconnect the accelerator controls cable from the accelerator cable bracket. Disconnect the cruise control cable from the throttle lever and accelerator bracket, if applicable. (Scheme 37)
2. Disconnect the air cleaner intake duct from the throttle body. See «AIR CLEANER INTAKE DUCT»(ref-155806-S21744190612003070700000) under AIR INDUCTION SYSTEMS. Disconnect the wire harness from the retainer. Remove the nut and bolts holding the accelerator cable bracket to the throttle body. Remove the accelerator cable bracket.

Position the accelerator cable bracket on the throttle body. Install the accelerator cable bracket nut and bolts. Tighten the bolts/nut in sequence to specification. (Scheme 38) See TORQUE SPECIFICATIONS. Install the wire harness into the retainer. Install the air cleaner intake duct. Connect the accelerator controls cable to the accelerator cable bracket. Connect the accelerator controls cable cross slug to the throttle body lever. Connect the cruise control cable to the throttle lever and accelerator bracket, if applicable.

Scheme 36

Scheme 37

Scheme 38

1. Remove the push-in retainers from the Insulator Panel (IP) insulator to instrument panel. Remove the press-on retainers from the IP insulator to dash mat. Unsnap the IP courtesy lamp from the IP insulator. Remove the IP insulator from the instrument panel.
2. Disconnect the accelerator cable from the accelerator pedal. Remove the fasteners holding the accelerator pedal to the bulk head. (Scheme 39) Remove the accelerator pedal. To install, reverse removal procedures. Tighten accelerator bolts and studs to specification. See «TORQUE SPECIFICATIONS»(ref-155806-S21244843402003062600000).
3. Check for complete throttle opening and closing positions by operating the accelerator pedal. Also inspect the carpet fit under the accelerator pedal. Reinstall the left instrument panel sound insulator.

Scheme 39