Engine Control System & Fuel System - 3.5l - Repair Instructions Pontiac G6 I final

Scheme 11

Crankshaft Position System Variation Learn

1. Install a scan tool.
2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(/pontiac/g6/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-trouble-code-dtc-list) for the applicable DTC that set.
3. With a scan tool, select the CKP System Variation Learn Procedure and perform the following: Block drive wheels. Set parking brake. DO NOT apply brake pedal. Cycle ignition from OFF to ON. Apply and hold brake pedal for the duration of the procedure. Start and idle engine. Turn the air conditioning (A/C) OFF. The vehicle must remain in Park or Neutral. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. Accelerate to wide open throttle (WOT) and release when the fuel cut-off occurs.
4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, or another DTC is present, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(/pontiac/g6/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-trouble-code-dtc-list) and perform the appropriate diagnostic procedure.
5. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully in order to store the CKP system variation values in the ECM memory.

Description

The engine control module (ECM) learns the airflow through the throttle body to ensure the correct idle. The learned airflow values are stored within the ECM. These values are learned to adjust for production variation and will continuously learn during the life of the vehicle to compensate for reduced airflow due to throttle body coking. Anytime the throttle body airflow rate changes, for example due to cleaning or replacing, the values must be relearned.

An engine that had a heavily coked throttle body that has been cleaned or replaced may take several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability to reset all learned values back to zero. A new ECM will also have values set to zero.

The idle may be unstable or a DTC may set if the learned values do not match the actual airflow.

Conditions for Running the Throttle Learn Procedure

Reset Procedure

1. DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120, P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205, P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606, P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128, P2135, P2138, or P2176 are not set.
2. Ignition ON, engine OFF.
3. The vehicle speed sensor (VSS) is 0 km/h (0 mph).

Learn Procedure

1. DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120, P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205, P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606, P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128, P2135, P2138, or P2176 are not set.
2. The engine speed is between 450-4,000 RPM.
3. The manifold absolute pressure (MAP) is greater than 5 kPa.
4. The mass air flow (MAF) is greater than 2 g/s.
5. The ignition voltage is greater than 10 volts.

Throttle Learn

Reset Procedure (Performed after the throttle body is cleaned or replaced)

1. Ignition ON, engine OFF, perform the Idle Learn Reset in Module Setup with a scan tool.
2. Start the engine and monitor the TB Idle Airflow Compensation parameter. The TB Idle Airflow Compensation value should equal 0 percent and the engine should be idling at a normal idle speed.
3. Clear the DTCs and return to the diagnostic that referred you here.

Learn Procedure (Performed after the ECM is flashed or replaced)

1. Start and idle the engine for 3 minutes.
2. With a scan tool, monitor the Desired Idle Speed and the actual Engine Speed.
3. The ECM will start to learn the new idle cells and Desired Idle Speed should start to decrease.
4. Ignition OFF for 60 seconds.
5. Start and idle the engine for 3 minutes.
6. After the 3 minute run time the engine should be idling normal. NOTE: During the drive cycle the check engine light may come on with idle speed DTCs. If idle speed codes are set, clear codes so the ECM can continue to learn. If the engine idle speed has not been learned the vehicle will need to be driven at speeds above 70 km/h (44 mph) with several decelerations and extended idles.
7. After the drive cycle, the engine should be idling normally. If the engine idle speed has not been learned, turn OFF the ignition for 60 seconds and repeat step 6.
8. Once the engine speed has returned to normal, clear DTCs and return to the diagnostic that referred you here.

Removal Procedure

1. Partially drain the cooling system. Refer to «Cooling System Draining and Filling (LY7, LZE, LZ4, LZ9)»(/pontiac/g6/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
3. Remove the ECT sensor.

Installation Procedure

1. Coat the threads with sealer GM P/N 13246004 (Canadian P/N 10953480) or equivalent.
2. Install the ECT sensor. Tighten: Tighten the ECT sensor to 20 N.m (15 lb ft).
3. Connect the ECT electrical connector.
4. Fill the cooling system. Refer to «Cooling System Draining and Filling (LY7, LZE, LZ4, LZ9)»(/pontiac/g6/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .

Scheme 12

1. Remove the positive crankcase ventilation (PCV) fresh air tube from the air cleaner intake duct.
2. Disconnect the mass air flow (MAF) sensor electrical connector (1).
3. Loosen the clamps and remove the air cleaner intake duct with the MAF sensor from the throttle body and the air cleaner housing cover.
4. Loosen the clamp and remove the MAF sensor from the air cleaner intake duct.

1. Install the MAF sensor to the air cleaner intake duct. Tighten: Tighten the clamp to 2 N.m (18 lb in).
2. Install the air cleaner intake duct with the MAF sensor to the throttle body and the air cleaner housing cover. Tighten: Tighten the clamps to 2 N.m (18 lb in).
3. Connect the MAF sensor electrical connector (1).
4. Install the PCV fresh air tube to the air cleaner intake duct.
5. Start and idle the engine.
6. Inspect the air intake duct for leaks.

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/pontiac/g6/i-final-2010-2010/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
3. Remove the MAP sensor attaching screw.
4. Remove the MAP sensor and MAP sensor seal from the upper intake manifold.

1. Install the MAP sensor and MAP sensor seal into the upper intake manifold.
2. Install the MAP sensor attaching screw. Tighten: Tighten the attaching screw to 6.5 N.m (57 lb in).
3. Connect the MAP sensor electrical connector.
4. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/pontiac/g6/i-final-2010-2010/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .

Special Tools

J 39194-B Heated Oxygen Sensor Wrench

1. Disconnect the heated oxygen sensor (HO2S) 1 electrical connector.
2. Use the J 39194-B to remove the HO2S 1.

1. Coat the threads of the HO2S 1 with anti-seize compound GM P/N 12377953 or an equivalent, if necessary.
2. Install the HO2S 1. Tighten: Use the J 39194-B to tighten the sensor to 41 N.m (30 lb ft).
3. Connect the H02S 1 electrical connector.

J 39194-B Heated Oxygen Sensor Wrench

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/g6/i-final-2010-2010/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
2. Remove the connector position assurance (CPA) retainer (1).
3. Disconnect the HO2S electrical connector (2).
4. Using the J 39194-B , remove the HO2S (1).

1. Coat the threads of the HO2S 2 with anti-seize compound GM P/N 12377953 or an equivalent, if necessary.
2. Install the HO2S (1). Tighten: Use the J 39194-B to tighten the sensor to 41 N.m (30 lb ft).
3. Connect the H02S electrical connector (2).
4. Install the CPA retainer (1).
5. Lower the vehicle.

J 39194-B Heated Oxygen Sensor Wrench

1. Disconnect the heated oxygen sensor (HO2S) 1 electrical connector.
2. Use the J 39194-B to remove the HO2S 1.

1. Coat the threads of the HO2S 1 with anti-seize compound GM P/N 12377953 or an equivalent, if necessary.
2. Install the HO2S 1. Tighten: Use the J 39194-B to tighten the sensor to 41 N.m (30 lb ft).
3. Connect the H02S 1 electrical connector.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/g6/i-final-2010-2010/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
2. Remove the connector position assurance (CPA) retainer (2).
3. Disconnect the HO2S electrical connector (1).
4. Using the J 39194-B , remove the HO2S (1).

1. Coat the threads of the HO2S 2 with anti-seize compound GM P/N 12377953 or an equivalent, if necessary.
2. Install the HO2S (1). Tighten: Use the J 39194-B to tighten the sensor to 41 N.m (30 lb ft).
3. Connect the H02S electrical connector (1).
4. Install the CPA retainer (2).
5. Lower the vehicle.

1. Disconnect the accelerator pedal position (APP) sensor electrical connector.
2. Remove the APP sensor bolts (1).
3. Remove the APP sensor (2).

1. Install the APP sensor (2).
2. Install the APP bolts (1) and tighten to 10 N.m (89 lb in).
3. Connect the APP sensor electrical connector.
4. Confirm that the APP sensor connector locking clip is fully secured.

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
2. Disconnect the electronic throttle control (ETC) electrical connector.
3. Remove the heater pipe nut at the throttle body.
4. Remove the nuts and the bolts from the throttle body.
5. Remove the throttle body assembly.
6. Remove the throttle body gasket.
7. Clean and inspect the throttle body gasket mating surfaces.

1. Install a new gasket, if necessary.
2. Install the throttle body assembly.
3. Install the throttle body nuts and the bolts. Tighten: Tighten the nuts and the bolts to 10 N.m (89 lb in).
4. Install the heater pipe nut to the throttle body. Tighten: Tighten the nut to 25 N.m (18 lb ft).
5. Connect the ETC electrical connector.
6. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
7. Perform the Throttle Learn Procedure. Refer to «Throttle/Idle Learn»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-36l-repair-instructions) .

Throttle Body Cleaning

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) . WARNING: Turn OFF the ignition before inserting fingers into the throttle bore. Unexpected movement of the throttle blade could cause personal injury. CAUTION: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate.
2. Inspect the throttle body bore and the throttle plate for deposits. You will need to open the throttle plate in order to inspect all surfaces. CAUTION: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components.
3. Clean the throttle body bore and the throttle plate using a clean shop towel with GM Top Engine Cleaner, P/N 1052626 or AC-Delco Carburetor Tune-Up Conditioner, P/N X66-P, or an equivalent product.
4. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
5. Perform the Throttle Learn Procedure. Refer to «Throttle/Idle Learn»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-36l-repair-instructions) .

Fuel Pressure Relief (Without CH 48027)

1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to «Electrical Center Identification Views»(/pontiac/g6/i-final-2010-2010/remont/electrical-component-locations/#wiring-systems-and-power-management-component-locator-electrical-center-identification-views) .
2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure.
3. Remove the engine cover, if required.
4. Remove the fuel rail service port cap.
5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve.
6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
7. Install the fuel rail service port cap.
8. Install the engine cover, if required.
9. Tighten the fuel fill cap.

CH-48027 Digital Pressure Gauge

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Without CH 48027)»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-24l-repair-instructions__fuel-pressure-relief-without-ch-48027) .
2. Connect the CH-48027-1 (1) to the CH-48027-2 (2).
3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's directions.

1. Relieve the fuel system pressure, if required. Perform the following steps: WARNING: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. Wrap a shop towel around the fuel rail service port. Place the hose on the CH-48027-2 (2) into an approved gasoline container. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. Close the valve on the CH-48027-2 (2). Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
4. Disconnect the CH-48027-3 (4) from the fuel rail service port.
5. Install the fuel rail service port cap.
6. Install the engine cover, if required.
7. Tighten the fuel fill cap.

J 37088-A Fuel Line Disconnect Tool Set

1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the «Fuel Pressure Relief (Without CH 48027)»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-24l-repair-instructions__fuel-pressure-relief-without-ch-48027) .
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 for the size of the fitting. Insert the tool into the female connector, then push inward in order to release the locking tabs.
5. Pull the connection apart.
6. Use a clean shop towel in order to wipe off the male pipe end.
7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required.

1. Apply a few drops of clean engine oil to the male pipe end.
2. Push both sides of the fitting together in order to snap the retaining tabs into place.
3. Once installed, pull on both sides of the fitting in order to make sure the connection is secure.
4. Install the retainer to the quick-connect fitting.

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Without CH 48027)»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-24l-repair-instructions__fuel-pressure-relief-without-ch-48027) .
2. Blow dirt out of the fitting using compressed air.
3. Squeeze the plastic tabs of the male end connector.
4. Pull the connection apart.
5. Wipe off the male pipe end using a clean shop towel.
6. Inspect both ends of the fitting for dirt and burrs.
7. 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 quick-connect fitting together in order to cause the retaining tabs to snap into place.
3. Pull on both sides of the quick connect fitting in order to make sure the connection is secure.

Fuel Tank Draining (Non E-85)

Special Tools

1. J 36850 Transjel Lubricant
2. J 42960-2 Fuel Flapper Door Holder
3. J 45004 Fuel Tank Drain Hose

1. Remove the fuel fill cap.
2. Install the J 42960-2 into the fuel fill pipe in order to hold the door open.
3. Insert the J 45004 into the fuel tank until the hose reaches the bottom of the fuel tank.
4. Use a hand or air operated pump device in order to drain as much fuel through the fuel fill pipe as possible.

Fuel Tank Draining (E-85)

Special Tools

1. J 36850 Transjel Lubricant
2. J 45004 Fuel Tank Drain Hose

1. Insert the J 45004 into the fuel tank (1) until the hose reaches the bottom of the fuel tank.
2. Use a hand or air operated pump device in order to drain as much fuel through the fuel fill pipe as possible.

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Without CH 48027)»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-24l-repair-instructions__fuel-pressure-relief-without-ch-48027) .
2. Drain the fuel tank. Refer to «Fuel Tank Draining (Non E-85)»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-24l-repair-instructions__fuel-tank-draining-non-e-85) «Fuel Tank Draining (E-85)»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions__fuel-tank-draining-e-85) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/g6/i-final-2010-2010/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
4. Loosen the fuel fill pipe hose clamp (1) at the fuel tank.
5. Disconnect the vapor recirculation line quick connect fitting (2). Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
6. Disconnect the fuel fill pipe hose from the fuel tank.
7. Release the exhaust pipe insulators from the underbody hangers.
8. Release the muffler insulator from the underbody hanger and slowly lower the exhaust to rest on a tall jackstand. If this is not possible, remove the rear half of the exhaust system at the take down flange.
9. If applicable, disengage the rear antilock brake system (ABS) wiring harness connector clip from the side of the EVAP canister bracket.
10. Disconnect the fuel tank jumper electrical connector from the underbody wiring harness.
11. Disengage the underbody wiring harness connector clip from the EVAP canister bracket.
12. Use an appropriate adjustable jack to support the fuel tank during removal.
13. Remove the fuel tank strap bolts.
14. Remove the fuel tank straps.
15. Using the adjustable jack, lower the fuel tank slightly in order to access the fuel line connections.
16. Disconnect the fuel feed (2) and vapor (1) line quick connect fittings. Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
17. Cap or plug the fuel feed and vapor lines in order to prevent fuel loss and/or system contamination.
18. In order to clear the exhaust pipe, slowly lower the right side of the fuel tank.
19. Once the tank is clear of the right frame rail, remove the fuel tank down and forward toward the right side of the vehicle.
20. If the fuel tank is being replaced, disconnect and remove the fuel tank electrical harness.
21. If the fuel tank is being replaced, perform the following: Disconnect and remove the fuel tank vapor line. Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) . Remove the EVAP canister. Refer to «Evaporative Emission Canister Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) . Remove the EVAP canister vent solenoid valve. Refer to «Evaporative Emission Canister Vent Solenoid Valve Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) . Remove the fuel pump module. Refer to «Fuel Tank Fuel Pump Module Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-24l-repair-instructions) .

1. If the fuel tank is being replaced, perform the following: Install the fuel pump module. Refer to «Fuel Tank Fuel Pump Module Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-24l-repair-instructions) . Install the EVAP canister vent solenoid valve. Refer to «Evaporative Emission Canister Vent Solenoid Valve Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) . Install the he EVAP canister. Refer to «Evaporative Emission Canister Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) . Install and connect the fuel tank vapor line. Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
2. If the fuel tank is being replaced, install and connect the fuel tank electrical harness.
3. Begin to install the left side of the fuel tank over the exhaust pipe.
4. Raise the right side of the fuel tank into position inboard of the right frame rail. Use care in feeding the fuel feed, EVAP vapor line, and the fuel sender electrical harness over the exhaust system.
5. Remove the caps or plugs from the fuel feed and vapor lines.
6. Connect the fuel feed (2) and vapor (1) line quick connect fittings. Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
7. Completely raise and install the fuel tank into position.
8. Install the fuel tank straps.
9. Install the fuel tank strap bolts and tighten to 20 N.m (15 lb ft).
10. Remove the adjustable jack from under the fuel tank.
11. Connect the fuel tank jumper electrical connector to the underbody wiring harness.
12. Engage the underbody wiring harness connector clip to the EVAP canister bracket.
13. If applicable, engage the rear ABS wiring harness connector clip to the side of the EVAP canister bracket.
14. Raise the exhaust into position and install the muffler insulator to the underbody hanger.
15. Install the exhaust extension pipe insulators to the underbody hangers.
16. Connect the fuel fill pipe hose to the fuel tank.
17. Tighten the fuel fill pipe hose clamp (1) at the fuel tank and tighten to 4 N.m (35 lb in).
18. Connect the vapor recirculation line quick connect fitting (2). Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
19. Lower the vehicle.
20. Refill the fuel tank.
21. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/pontiac/g6/i-final-2010-2010/remont/charging-system/#battery-charging-system-and-starting-system) .
22. Inspect for fuel leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.

J-45722: Fuel Sender Lock Ring Wrench

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-24l-repair-instructions) .
2. Disconnect the fuel pressure sensor and sender electrical connections.
3. Disconnect the evaporative emission (EVAP) vapor line quick connect fittings (1, 2). Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-24l-repair-instructions) .
4. Disengage the fuel feed line from the retaining features built into the fuel tank.
5. Use the J-45722: wrench and a long breaker-bar in order to unlock the fuel sender lock ring.
6. Raise the fuel sender assembly out of the tank far enough to access the vapor line quick connect fitting (1) on the underside of the sender cover.
7. Disconnect the vapor line quick connect fitting (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-24l-repair-instructions) .
8. Remove the fuel sender assembly (2) from the fuel tank.

1. Install a NEW O-ring seal (3) onto the fuel sender.
2. Install the fuel sender assembly (2) into the fuel tank far enough to connect the vapor line quick connect fitting on the underside of the sender cover.
3. Connect the vapor line quick connect fitting (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-24l-repair-instructions) .
4. Align the cover "paddle" or anti-rotation feature with the corresponding feature in the top of the fuel tank.
5. Slowly apply pressure to the top of the spring loaded sender cover until the sender aligns flush with the surface of the tank.
6. Use the J-45722: wrench in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction.
7. Turn the lock ring until the ring seats on the second detent.
8. Engage the fuel feed line to the retaining features built into the fuel tank.
9. Connect the EVAP vapor line quick connect fittings (1, 2). Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-24l-repair-instructions) .
10. Connect the fuel pressure sensor and sender electrical connections.
11. Install the fuel tank. Refer to «Fuel Tank Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-24l-repair-instructions) .
12. Lower the vehicle.
13. Refill the tank.
14. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/pontiac/g6/i-final-2010-2010/remont/charging-system/#battery-charging-system-and-starting-system) .
15. Inspect for fuel leaks through the following steps: Turn the ignition to the ON position for 2 seconds. Turn the ignition to the OFF position for 10 seconds. Turn the ignition to the ON position. Inspect for fuel leaks.

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
2. Disconnect the fuel tank pressure sensor electrical connector.
3. Remove the fuel tank pressure sensor.

1. Install the NEW fuel tank pressure sensor.
2. Connect the fuel tank pressure sensor electrical connector.
3. Install the fuel tank. Refer to «Fuel Tank Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .

Scheme 13

1. Drain the fuel tank. Refer to «Fuel Tank Draining (Non E-85)»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-24l-repair-instructions__fuel-tank-draining-non-e-85) «Fuel Tank Draining (E-85)»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions__fuel-tank-draining-e-85) .
2. Remove the fuel fill pipe bolt from the fuel fill pocket.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/g6/i-final-2010-2010/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
4. Remove the fuel fill pipe bolt from the underbody.
5. Loosen the fuel fill pipe hose clamp (1) at the fuel tank.
6. Disconnect the vapor recirculation line quick connect fitting (2). Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
7. Disconnect and remove the fuel fill pipe hose assembly.

1. Install and connect the fuel fill pipe hose assembly.
2. Tighten the fuel fill pipe hose clamp (1) at the fuel tank and tighten to 4 N.m (35 lb in).
3. Connect the EVAP canister vent solenoid tube quick connect fitting (2). Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
4. Install the fuel fill pipe bolt to the underbody and tighten to 10 N.m (89 lb in).
5. Lower the vehicle.
6. Install the fuel fill pipe bolt to the fuel fill pocket and tighten to 1.5 N.m (13 lb in).

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/pontiac/g6/i-final-2010-2010/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Without CH 48027)»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-24l-repair-instructions__fuel-pressure-relief-without-ch-48027) .
3. Disconnect the engine fuel feed pipe from the chassis fuel flex hose. Refer to «Metal Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
4. Disconnect the engine fuel feed pipe from the Fuel Rail. Refer to «Metal Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
5. Remove the two fuel feed pipe fasteners.
6. Remove the engine fuel feed pipe.

1. Install the fuel feed pipe to the fuel rail Refer to «Metal Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
2. Install the engine fuel feed pipe fasteners located on the engine. Tighten: Tighten the fuel feed pipe fasteners to 10 N.m (89 lb in).
3. Connect the engine fuel feed pipe to the chassis fuel flex hose. Refer to «Metal Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
4. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/pontiac/g6/i-final-2010-2010/remont/charging-system/#battery-charging-system-and-starting-system) .
5. Inspect for leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Inspect for fuel leaks. Turn OFF the ignition for 10 seconds. Turn ON the ignition.
6. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/pontiac/g6/i-final-2010-2010/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/pontiac/g6/i-final-2010-2010/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Without CH 48027)»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-24l-repair-instructions__fuel-pressure-relief-without-ch-48027) .
3. Disconnect the fuel feed pipe from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
4. Cap or plug the fuel feed pipe and the fuel rail to in order to system prevent contamination.
5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/g6/i-final-2010-2010/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
6. Disconnect the fuel feed pipe quick connect fitting at the fuel tank. Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
7. Remove the rear brake pipe bracket nuts and release the brackets from the body studs.
8. Release the pipe retainers from the vehicle underbody.
9. Remove the fuel feed pipe from the pipe retainers.
10. Lower the rear of the pipe while moving the pipe rearward slightly, then lower the front of the pipe.
11. Remove the fuel feed pipe from the vehicle.

1. Position the fuel feed pipe to the vehicle.
2. With the rear of the pipe positioned slightly rearward and down, raise the front of the pipe into position.
3. Install the remainder of the pipe into position.
4. Install the fuel feed pipe to the pipe retainers.
5. Secure the pipe retainers to the vehicle underbody.
6. Connect the fuel feed pipe quick connect fitting at the fuel tank. Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
7. Lower the vehicle.
8. Remove the caps or plugs from the fuel pipe and the fuel rail.
9. Connect the fuel feed pipe to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
10. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/pontiac/g6/i-final-2010-2010/remont/charging-system/#battery-charging-system-and-starting-system) .
11. Inspect for fuel leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
12. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/pontiac/g6/i-final-2010-2010/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .

Fuel System Cleaning

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
2. Remove the fuel pump module assembly. Refer to «Fuel Tank Fuel Pump Module Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-24l-repair-instructions) .
3. Inspect the fuel pump module strainer. Replace the pump module assembly if the fuel strainer is contaminated.
4. Flush the fuel tank with hot water.
5. 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.
6. Allow the tank to dry completely before reassembly.
7. Disconnect the fuel feed pipe at the engine fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
8. Clean the fuel pipes by applying air pressure in the opposite direction of the fuel flow.
9. Connect the fuel feed pipe to the engine fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
10. Install the fuel pump module assembly. Refer to «Fuel Tank Fuel Pump Module Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-24l-repair-instructions) .
11. Install the fuel tank. Refer to «Fuel Tank Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .

An 8-digit identification number is stamped on the fuel rail. Refer to this number if servicing or part replacement is required.

1. Remove the engine fuel feed pipe from the fuel rail.
2. Relieve fuel system pressure. Refer to «Fuel Pressure Relief (Without CH 48027)»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-24l-repair-instructions__fuel-pressure-relief-without-ch-48027) .
3. Remove the upper intake manifold. Refer to «Upper Intake Manifold Replacement»(/pontiac/g6/i-final-2010-2010/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
4. Disconnect the main injector harness electrical connector.
5. Disconnect the main fuel injector electrical harness connector.
6. Pull up the lock release (2) of the fuel injector electrical connectors.
7. Depress the lock tabs (1) and disconnect the fuel injector electrical connectors.
8. Remove the fuel injector electrical wiring harness from the fuel rail.
9. Remove the fuel rail bolts.
10. Remove the fuel rail assembly.
11. Remove the fuel injector O-ring seal from the spray tip end of each injector.
12. Remove and discard O-rings if damaged.

1. Replace any damaged O-ring seals that were removed.
2. Lubricate the O-ring seals with clean engine oil.
3. Install the fuel rail assembly into the intake manifold. Tilt the fuel rail assembly slightly to install the injectors.
4. Install the fuel rail bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Install the fuel injector electrical wiring harness to the fuel rail.
6. Connect the fuel injector electrical connectors.
7. Push the slide locks (2) into position.
8. Connect the main fuel injector electrical harness connector.
9. Install the fuel feed pipe to the fuel rail.
10. Install the upper intake manifold. Refer to «Upper Intake Manifold Replacement»(/pontiac/g6/i-final-2010-2010/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
11. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/pontiac/g6/i-final-2010-2010/remont/charging-system/#battery-charging-system-and-starting-system) .
12. Inspect for fuel leaks with the following procedure: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.

1. Remove the fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
2. Remove the fuel injector retaining clip (1).
3. Remove the fuel injector (3) from the fuel rail.
4. Remove the fuel injector upper O-ring (2).
5. Remove the fuel injector lower O-ring (4).

1. The fuel injector assembly (1) is stamped with a part number identification (2).
2. Lubricate the new injector O-rings (2, 4) with clean engine oil.
3. Install the fuel injector upper O-ring (2).
4. Install the fuel injector lower O-ring (4).
5. Install the fuel injector (3) to the fuel rail.
6. Install the fuel injector retaining clip (1).
7. Install the fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .

1. Disconnect the evaporative emission (EVAP) canister purge valve electrical connector.
2. Disconnect the EVAP canister purge pipe from the EVAP canister purge valve. Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
3. Remove the EVAP canister purge valve bolt.
4. Remove the EVAP canister purge valve from the intake manifold.

1. Position the EVAP canister purge valve to the intake manifold.
2. Install the EVAP canister purge valve bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
3. Connect the EVAP canister purge pipe to the EVAP canister purge valve. Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
4. Connect the EVAP canister purge valve electrical connector.

1. Lower the fuel tank enough on the right side in order to access the evaporative emission (EVAP) canister vent solenoid valve. Refer to «Fuel Tank Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) . It is not necessary to completely remove the fuel tank from the vehicle.
2. Disconnect the EVAP canister vent solenoid valve tube quick connect fitting (2). Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
3. Disconnect the EVAP canister vent solenoid valve electrical connector (2).
4. Disconnect the EVAP canister vent tube quick connect fitting (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
5. Depress the locking tab on the EVAP canister vent solenoid valve mount and slide the valve rearward off of the fuel tank.

1. Install the EVAP canister vent solenoid valve onto the mount on the fuel tank, push the valve forward until the locking tab engages.
2. Connect the EVAP canister vent tube quick connect fitting (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
3. Connect the EVAP canister vent solenoid valve electrical connector (2).
4. Connect the EVAP canister vent solenoid valve tube quick connect fitting (2). Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
5. Raise the fuel tank completely on the right side. Refer to «Fuel Tank Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
2. Disconnect the evaporative emission (EVAP) vapor line quick connect fittings from the fuel sender. Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
3. Disconnect the EVAP vapor line quick connect fitting at the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
4. Cap or plug the EVAP connections and the fuel sender and canister in order to prevent system contamination.
5. Remove the EVAP vapor line from the fuel tank.

1. Remove the EVAP vapor line from the fuel tank.
2. Remove the caps or plugs from the EVAP vapor line connections.
3. Connect the EVAP vapor line quick connect fittings at the fuel sender. Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
4. Connect the EVAP vapor line quick connect fitting at the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
5. Install the fuel tank. Refer to «Fuel Tank Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/pontiac/g6/i-final-2010-2010/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Without CH 48027)»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-24l-repair-instructions__fuel-pressure-relief-without-ch-48027) .
3. Disconnect the evaporative emission (EVAP) vapor line quick connect fitting from the purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
4. Cap or plug the EVAP vapor line and the purge solenoid in order to prevent system contamination.
5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/g6/i-final-2010-2010/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
6. Disconnect the EVAP vapor line quick connect fitting at the fuel tank. Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
7. Remove the rear brake pipe bracket retaining nuts and release the brackets from the body studs.
8. Release the pipe retainers from the vehicle underbody.
9. Remove the EVAP vapor line from the pipe retainers.
10. Lower the rear of the pipe while moving the pipe rearward slightly, then lower the front of the pipe.
11. Remove the EVAP vapor line from the vehicle.

1. Position the EVAP vapor line to the vehicle.
2. With the rear of the line positioned slightly rearward and down, raise the front of the line into position.
3. Install the remained of the line into position.
4. Install the EVAP vapor line to the pipe retainers.
5. Secure the pipe retainers to the vehicle underbody.
6. Connect the EVAP vapor line quick connect fitting at the fuel tank. Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
7. Lower the vehicle.
8. Remove the caps or plugs from the EVAP vapor line and the purge solenoid.
9. Connect the EVAP vapor line quick connect fitting to the purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
10. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/pontiac/g6/i-final-2010-2010/remont/charging-system/#battery-charging-system-and-starting-system) .
11. Inspect for fuel leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
12. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/pontiac/g6/i-final-2010-2010/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
2. Disconnect the evaporative emission (EVAP) canister to EVAP canister vent solenoid valve line quick connect fitting. Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
3. Disconnect the fuel tank EVAP vapor line to EVAP canister quick connect fitting. Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
4. From under the fuel tank, remove the TORX® bolt attaching the EVAP canister to bracket.
5. Slide the EVAP canister upward from the bracket.

1. Slide the NEW EVAP canister down into the bracket.
2. From under the fuel tank, install the TORX® bolt attaching the EVAP canister to bracket. Tighten: Tighten the bolt to 10 N.m (89 lb in).
3. Connect the fuel tank EVAP vapor line to EVAP canister quick connect fitting. Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
4. Connect the EVAP canister to EVAP canister vent solenoid valve line quick connect fitting. Refer to «Plastic Collar Quick Connect Fitting Service»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
5. Install the fuel tank. Refer to «Fuel Tank Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .

1. Note the position of the spark plug wires for the installation and disconnect the spark plug wires from the ignition coil and module assembly.
2. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/pontiac/g6/i-final-2010-2010/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
3. Remove the 4 screws securing the ignition coil and module assembly to the bracket.
4. Remove the ignition coil and module assembly.

1. Install the ignition coil and module assembly to the bracket.
2. Install the ignition coil and module assembly screws. Tighten: Tighten the screws to 4.5 N.m (40 lb in).
3. Connect the spark plug wires as noted during the removal.
4. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/pontiac/g6/i-final-2010-2010/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .

1. Note the position of the spark plug wires for the installation and disconnect the spark plug wires from the ignition coil and module assembly.
2. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/pontiac/g6/i-final-2010-2010/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
3. Remove the 4 screws securing the ignition coil and module assembly to the bracket.
4. Remove the ignition coil and module assembly.

1. Install the ignition coil and module assembly to the bracket.
2. Install the ignition coil and module assembly screws. Tighten: Tighten the screws to 4.5 N.m (40 lb in).
3. Connect the spark plug wires as noted during the removal.
4. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/pontiac/g6/i-final-2010-2010/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
5. Refer to «Control Module References»(/pontiac/g6/i-final-2010-2010/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) for programming and setup information.

Spark Plug Wire Inspection

Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Refer to the list below for items to be inspected.

1. Inspect for correct routing of the spark plug wires. Improper routing may cause cross-firing. Refer to «Spark Plug Wire Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
2. Inspect each wire for any signs of cracks or splits in the wire.
3. Inspect each boot for the following conditions: Tearing Piercing Arcing Carbon Tracking Corroded terminal

If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal both the wire and the component connected to the wire should be replaced.

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/pontiac/g6/i-final-2010-2010/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
2. Remove the spark plug wires (2, 4, and 6) from the engine left side spark plugs.
3. Remove the spark plug wires from the retaining clips.
4. Remove the spark plug wires (1, 3, and 5) from the engine right side spark plugs.
5. Remove the spark plug wires from the retaining clip.
6. Remove the spark plug wires (1-6) from the ignition coils.
7. Remove the spark plug wires from the engine.
8. If you are replacing the spark plug wires, transfer any of the following components: Spark plug wire conduit Spark plug wire retaining clips

1. Install the spark plug wires (1-6) to the engine.
2. Install the spark plug wires to the ignition coils.
3. Install the spark plug wires (1, 3, and 5) to the engine right side spark plugs.
4. Install the spark plug wires to the retaining clip.
5. Install the spark plug wires (2, 4, and 6) to the engine left side spark plugs.
6. Install the spark plug wires to the retaining clips.
7. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/pontiac/g6/i-final-2010-2010/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .

Spark Plug Usage

1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to «Ignition System Specifications»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-specifications__ignition-system-specifications) for the correct spark plug.
2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling-Colder plug Pre-ignition causing spark plug and/or engine damage-Hotter plug

Spark Plug Inspection

1. Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move.
2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground.
3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4).
4. Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to «Ignition System Specifications»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-specifications__ignition-system-specifications) . An excessively wide electrode gap can prevent correct spark plug operation. Inspect for the correct spark plug torque. Refer to «Ignition System Specifications»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-specifications__ignition-system-specifications) . Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). Inspect for a broken or worn side electrode (3). Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. A loose center electrode (4) reduces the spark intensity. Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. Inspect for worn or missing platinum pads on the electrodes (3, 4) If equipped. Inspect for excessive fouling.
5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation.

Spark Plug Visual Inspection

1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives.
2. Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors Excessive fuel pressure Restricted air filter element Incorrect combustion Reduced ignition system voltage output Weak coils Worn ignition wires Incorrect spark plug gap Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off.
3. Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode.

1. If you are replacing the engine left bank spark plugs, remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
2. Remove the spark plug wires from the spark plugs. Refer to «Spark Plug Wire Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
3. Remove the spark plugs from the engine.

1. Gap the spark plugs to the specifications. Refer to «Ignition System Specifications»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-specifications__ignition-system-specifications) .
2. Install the spark plugs to the engine. Tighten: If installing the spark plugs to a new cylinder head tighten the plugs to 20 N.m (15 lb ft). If installing the spark plugs to an existing cylinder head tighten the plugs to 15 N.m (11 lb ft).
3. Install the spark plug wires to the spark plugs. Refer to «Spark Plug Wire Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/g6/i-final-2010-2010/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
2. Disconnect the crankshaft position (CKP) sensor electrical connector.
3. Remove the CKP sensor bolt.
4. Remove the CKP sensor.
5. Inspect for wear, cracks, or leakage if the sensor is not being replaced.

1. Lubricate the O-ring with clean engine oil before installation and replace the O-ring if necessary.
2. Install the CKP sensor.
3. Install the CKP sensor bolt. Tighten: Tighten the bolt to 11 N.m (97 lb in).
4. Connect the CKP sensor electrical connector.
5. Lower the vehicle.
6. Perform the CKP system variation learn procedure. Refer to «Crankshaft Position System Variation Learn»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions__crankshaft-position-system-variation-learn) .

1. Disconnect the camshaft position (CMP) sensor electrical connector.
2. Remove the CMP sensor bolt.
3. Remove the CMP sensor.
4. Inspect the sensor O-ring for wear, cracks, or leakage if the sensor is not being replaced.

1. Lubricate the O-ring with clean engine oil and replace the O-ring if damaged.
2. Install the CMP sensor.
3. Install the CMP sensor bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Connect the CMP sensor electrical connector.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/g6/i-final-2010-2010/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
2. Disconnect the engine wiring harness electrical connector (1) from the knock sensor.
3. Remove the knock sensor bolt and sensor.

1. Position the knock sensor to the engine block and install the knock sensor bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
2. Connect the engine wiring harness electrical connector (1) to the knock sensor.
3. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/g6/i-final-2010-2010/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
2. Disconnect the engine wiring harness electrical connector (2) from the knock sensor.
3. Remove the knock sensor bolt and sensor.

1. Position the knock sensor to the engine block and install the knock sensor bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
2. Connect the engine wiring harness electrical connector (2) to the knock sensor.
3. Lower the vehicle.

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

1. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
2. Remove the EGR pipe bolt and carefully pull the pipe assembly back.
3. Remove the EGR valve bolts.
4. Remove EGR valve.
5. Remove the EGR valve gasket.
6. Clean and inspect the EGR valve gasket mating surfaces.

1. Install a new EGR valve gasket.
2. Install the EGR valve.
3. Install the EGR valve bolts. Tighten: Tighten the bolt to 30 N.m (22 lb ft).
4. Install the EGR pipe to the EGR valve.
5. Install the EGR pipe. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
6. Connect the EGR valve electrical connector.

1. Remove the exhaust gas recirculation (EGR) pipe bolt and carefully pull the pipe assembly back.
2. Remove the EGR pipe assembly bolts from the exhaust manifold.
3. Remove the EGR pipe.

1. Install the EGR pipe to the exhaust manifold. Tighten: Tighten the EGR pipe bolts to 25 N.m (18 lb ft).
2. Install the EGR pipe to the EGR valve.
3. Install the EGR pipe bolt. Tighten: Tighten the bolt to 30 N.m (22 lb ft).

Exhaust Gas Recirculation (EGR) System Cleaning

Note. Whenever the 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.

Proper EGR system service consists of the following steps

1. Clean and inspect the EGR pipe from the exhaust manifold to the EGR valve. Refer to «Exhaust Gas Recirculation Pipe Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
2. Clean the EGR valve. The EGR valve can be removed, inspected for deposits, cleaned, and reinstalled. Use the following procedure for this operation: Remove the EGR valve from the engine. Refer to «Exhaust Gas Recirculation Valve Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) . 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. If deposits are such that pintle/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 engine, using a new gasket. Refer to «Exhaust Gas Recirculation Valve Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .

1. Remove the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/pontiac/g6/i-final-2010-2010/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
2. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/pontiac/g6/i-final-2010-2010/remont/frames-subframes-crossmembers/#frame-underbody) .
3. Remove the air cleaner inlet duct bolt and push pin retainers.
4. Remove the air cleaner inlet duct.

1. Install the air cleaner inlet duct.
2. Install the air cleaner inlet duct bolt and push pin retainers. Tighten: Tighten the bolt to 10 N.m (89 lb in).
3. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(/pontiac/g6/i-final-2010-2010/remont/frames-subframes-crossmembers/#frame-underbody) .
4. Install the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/pontiac/g6/i-final-2010-2010/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .

1. Remove the positive crankcase ventilation (PCV) fresh air tube from the air cleaner intake duct.
2. Loosen the air cleaner outlet duct clamps at the mass airflow (MAF) sensor and throttle body.
3. Remove the air outlet duct bolt (1).
4. Remove the air cleaner outlet duct.

1. Install the air cleaner outlet duct.
2. Install the air outlet duct bolt (1). Tighten: Tighten the bolt to 10 N.m (89 lb in).
3. Tighten the air cleaner outlet duct clamps at the MAF sensor and throttle body. Tighten: Tighten the clamps to 2 N.m (18 lb in).
4. Install the PCV fresh air tube to the air cleaner outlet duct.

Scheme 21

1. Disconnect the mass air flow (MAF) sensor harness connector.
2. Remove the upper air cleaner cover screws.
3. Remove the upper air cleaner cover.
4. Remove the air cleaner filter from the lower air cleaner housing.
5. Inspect the air cleaner filter for dust, dirt and water contamination.
6. Replace as necessary. Refer to «Maintenance Schedule (North American Emissions)»(/pontiac/g6/i-final-2010-2010/remont/lubrication-system/#maintenance-and-lubrication__maintenance-schedule-north-american-emissions) .

1. Install the air cleaner filter into the lower air cleaner housing.
2. Install the upper air cleaner cover to the lower air cleaner housing.
3. Secure the air cleaner housing cover. Tighten: Tighten the air cleaner cover screws to 5 N.m (44 lb in).
4. Connect the MAF sensor harness connector.

Scheme 22

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .
2. Remove the air cleaner assembly bolts.
3. Remove the air cleaner assembly.

1. Install the air cleaner assembly.
2. Install the air cleaner assembly bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
3. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/pontiac/g6/i-final-2010-2010/remont/testing-diagnostics/#engine-control-system-fuel-system-35l-repair-instructions) .

See also:
• Battery Negative Cable Disconnection and Connection
• Control Module References
• Diagnostic Trouble Code (DTC) List - Vehicle
• Cooling System Draining and Filling (LY7, LZE, LZ4, LZ9)
• Fastener Caution
• Intake Manifold Cover Replacement
• Heated Oxygen Sensor Resistance Learn Reset Caution
• Lifting and Jacking the Vehicle
• Throttle/Idle Learn
• Gasoline/Gasoline Vapors Warning
• Relieving Fuel Pressure Warning
• Electrical Center Identification Views
• Fuel Pressure Relief (Without CH 48027)
• Fuel Tank Draining (Non E-85)
• Fuel Tank Fuel Pump Module Replacement
• Ignition System Specifications
• Exhaust Manifold Replacement - Right Side (LY7)
• Tire and Wheel Removal and Installation
• Front Fender Liner Replacement
• Maintenance Schedule (North American Emissions)
• Air Cleaner Outlet Duct Replacement
• Fuel Tank Draining (E-85)
• Crankshaft Position System Variation Learn