Engine Controls - 6.0L - Troubleshooting: Removal & Installation Pontiac GTO IV

Engine Control Module (ECM) Replacement

Engine control module (ECM) service should normally consist of either ECM replacement or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures require ECM replacement, inspect the ECM first to see if the correct part is being used.

1. A battery cable
2. The ECM pigtail
3. The ECM fuse
4. Jumper cables

Removal Procedure

1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-201045-S04579536502005102400000) in Engine Electrical.
3. Remove the connector protection assurance (CPA) locks on each ECM electrical connector, then move the connector lock levers to the unlock position.
4. Disconnect the ECM electrical connectors.
5. Remove the two screws (1) securing the ECM to the mounting bracket
6. Remove the ECM.

Installation Procedure

1. Install the ECM to the mounting bracket.
2. Install the 2 screws (1) securing the ECM to the mounting bracket Tighten: Tighten the ECM fasteners to 1-3 N.m
3. Install the ECM electrical connectors.
4. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-201045-S04579536502005102400000) in Engine Electrical.
5. If a new ECM is being installed, program the ECM. Refer to «Service Programming System (SPS)»(ref-201100-S18496744742005102400000) in Programming and Setup.
6. Whenever the ECM or the negative battery cables have been disconnected, the crankshaft variation procedure must be performed. Refer to «CKP System Variation Learn Procedure»(ref-201043-S19765510982005102400000) .

1. Turn OFF the ignition.
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-201059-S03425061632005102400000) in General Information.
3. Drain the engine coolant below the level of the ECT sensor. Refer to «Draining and Filling Cooling System»(ref-201062-S03035929722005102400000) in Engine Cooling.
4. Lower the vehicle.
5. Remove the fuel rail cover.
6. Disconnect the electrical connector from the ECT sensor.
7. Remove the ECT sensor.

1. Coat the sensor threads with sealer P/N 12346004 (Canadian P/N 10953480) or the equivalent.
2. Install the ECT sensor. Tighten: Tighten the ECT sensor to 20 N.m (15 lb ft).
3. Connect the ECT sensor electrical connector.
4. Install the fuel rail cover.
5. Refill the engine coolant. Refer to «Draining and Filling Cooling System»(ref-201062-S03035929722005102400000) in Engine Cooling.

1. Disconnect the MAF/intake air temperature (IAT) sensor (2) wiring harness connector.
2. Loosen the clamp on air duct adaptor closest to the air cleaner upper housing (2).
3. Loosen the clamp on the intake air duct at the MAF sensor (1) and pull back the intake air duct to clear the sensor
4. Remove the MAF sensor (2). IMPORTANT: The air duct adaptor (between air cleaner and MAF sensor), retaining clamps, air duct and MAF sensor, all have locating notches.

1. Install the MAF sensor (2) into the air duct adaptor.
2. Install the MAF sensor into the air duct adaptor (2).
3. Install the retaining clamps, aligning notches, tighten clamps to the specified torque. Tighten: Tighten the retaining clamps to 2 N.m (17 lb in).
4. Connect the MAF/IAT sensor (2) wiring harness connector.

1. Remove the oil filler cap (1).
2. Remove the right engine sight shield (2).
3. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (3).
4. Remove the MAP sensor (714) from the intake manifold.

1. Install the MAP sensor (714).
2. Reconnect the MAP sensor electrical connector (3) to the engine wiring harness.
3. Install engine sight shield (2).
4. Install the oil filler cap (1).

Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1

Note. Refer to Heated Oxygen and Oxygen Sensor Notice in Cautions and Notices.

Note. Refer to Excessive Force and Oxygen Sensor Notice in Cautions and Notices.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-201059-S03425061632005102400000) in General Information.
2. Disconnect the HO2S electrical connector.
3. Carefully back out the heated oxygen sensor (HO2S).

1. Coat the threads of the heated oxygen sensor with anti-seize compound P/N 5613695, or an equivalent if necessary.
2. Install the heated oxygen sensor. Tighten: Tighten the HO2S to 41 N.m (30 lb ft).
3. Connect the HO2S electrical connector.
4. Lower the vehicle.

Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2

Note. Refer to Heated Oxygen and Oxygen Sensor Notice in Cautions and Notices.

Note. Refer to Excessive Force and Oxygen Sensor Notice in Cautions and Notices.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-201059-S03425061632005102400000) in General Information.
2. Disconnect the HO2S electrical connector.
3. Carefully back out the heated oxygen sensor.

1. Coat the threads of the heated oxygen sensor with anti-seize compound P/N 5613695, or the equivalent if necessary.
2. Install the heated oxygen sensor. Tighten: Tighten the HO2S to 41 N.m (30 lb ft).
3. Connect the HO2S electrical connector.
4. Lower the vehicle.

Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1

Note. Refer to Heated Oxygen and Oxygen Sensor Notice in Cautions and Notices.

Note. Refer to Excessive Force and Oxygen Sensor Notice in Cautions and Notices.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-201059-S03425061632005102400000) in General Information.
2. Disconnect the HO2S electrical connector.
3. Carefully back out the heated oxygen sensor.

1. Coat the threads of the heated oxygen sensor with anti-seize compound P/N 12377953, or the equivalent if necessary.
2. Install the heated oxygen sensor. Tighten: Tighten the HO2S to 41 N.m (30 lb ft).
3. Connect the HO2S electrical connector.
4. Lower the vehicle.

Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 2

Note. Refer to Heated Oxygen and Oxygen Sensor Notice in Cautions and Notices.

Note. Refer to Excessive Force and Oxygen Sensor Notice in Cautions and Notices.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-201059-S03425061632005102400000) in General Information.
2. Disconnect the HO2S electrical connector.
3. Carefully back out the heated oxygen sensor.

1. Coat the threads of the heated oxygen sensor with anti-seize compound P/N 12377953, or the equivalent if necessary.
2. Install the heated oxygen sensor. Tighten: Tighten the HO2S to 41 N.m (30 lb ft).
3. Connect the HO2S electrical connector.
4. Lower the vehicle.

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

1. Remove the screw (1) retaining the vacuum tank (2), and remove the vacuum tank.
2. Disconnect the electrical connector (1) of the accelerator pedal sensor module (2).
3. Remove the accelerator pedal mounting bolts (1).
4. Slide the APP sensor upwards, to disengage the sensor from the support bracket (3).
5. Remove the accelerator pedal (2).

1. Install the accelerator pedal.
2. Slide the APP sensor downwards, to engage the sensor to the support bracket (3).
3. Tighten: Tighten the accelerator pedal mounting bolts to 10 N.m (7 lb ft).
4. Connect the accelerator pedal sensor module electrical connector.
5. Inspect for complete throttle opening, and throttle closing positions by operating the accelerator pedal. Monitor the throttle angles using a scan tool. The accelerator pedal should operate freely without binding between full closed throttle, and wide open throttle.
6. Inspect for an incorrect carpet fit under the accelerator pedal.
7. Install the vacuum tank, and secure the retaining screw.

1. Remove the air intake duct from the throttle body. Refer to «Air Cleaner Assembly Replacement»(ref-201043-S28051882602005102400000) .
2. Remove the electrical wire harness connector from the throttle body.
3. Remove the throttle body bolts (538).
4. Remove the throttle body (508).
5. Remove the throttle body gasket (509), and discard.

1. Install the throttle body gasket (509) to the intake manifold. Align the locating tab of the gasket with the notch in the manifold.
2. Install the throttle body (508) and bolts (538). Tighten: Tighten the throttle body bolts to 10 N.m (89 lb in).
3. Install the electrical wire harness connector from the throttle body.
4. Install the air intake duct to the throttle body. Refer to «Air Cleaner Assembly Replacement»(ref-201043-S28051882602005102400000) .

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

1. Before you service any fuel system connection, relieve the fuel system pressure Refer to the «Fuel Pressure Relief Procedure»(ref-201043-S21654027382005102400000) .
2. Slide the dust cover from the quick-connect fitting.
3. Use compressed air in order to blow any dirt from the fitting.
4. Choose the correct tool for the size of the fitting from J 37088-A or EN-46843 quick release tool kits. See «Special Tools»(ref-201043-S19962986522005102400000) . Insert the selected tool into the female connector, then push inward in order to release the locking tabs.
5. Pull the connection apart.
6. Using a clean shop towel, wipe off the male pipe end.
7. Inspect both ends of the fitting for dirt and for 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 cause the retaining tabs to snap into place.
3. Once installed, pull on both sides of the fitting to make sure the connection is secure.
4. Reposition the dust cover over the quick-connect fitting.

1. Before you service any fuel system connection, relieve the fuel system pressure Refer to the «Fuel Pressure Relief Procedure»(ref-201043-S21654027382005102400000) .
2. Grasp both sides of the quick connect fitting and twist 1/4 turn in each direction in order to loosen any dirt.
3. Remove any dirt, dust, or other foreign material from the quick connect fitting with compressed air.
4. Squeeze the release tabs on the plastic retainer.
5. Pull the quick connect fuel fitting apart. Use a shop towel to catch any remaining fuel that may leak from the fuel line and the fitting.

1. Apply a few drops of clean engine oil to the end of the male fuel pipe.
2. Insert the male fuel pipe into the quick connect fitting.
3. Push both sides of the quick connect fitting together until the fitting clicks.
4. Pull and push repeatedly on both sides of the quick connect fitting in order to ensure that the connection is secure.

1. Siphon as much fuel as possible from the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-201043-S41971780112005102400000) .
2. Remove the rear compartment support brace to gain access to the fuel tank. Refer to «Support Brace Replacement - Rear Compartment»(ref-201066-S16165695192005102400000) in Body Rear End.
3. Disconnect the body wiring harness to fuel tank harness electrical connector (1).
4. From behind the fuel filler door (2) unscrew the fuel filler cap (3) and cover the end of the fuel filler neck with a suitable material to prevent foreign objects from entering.
5. Remove the 3 nuts (1) securing the fuel filler neck to the filler pocket (4).
6. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-201059-S03425061632005102400000) in General Information.
7. Disconnect the fuel feed line quick connect fitting (1), Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-201043-S03534227022005102400000) .
8. Disconnect the fuel tank to fuel feed line quick connect fitting (2). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-201043-S03534227022005102400000) , and place the feed line to one side.
9. Remove the fuel tank vent line quick connect fitting (2). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-201043-S03534227022005102400000) .
10. Remove the lower fuel tank mounting strap nuts (1).
11. Lower the vehicle and from within the rear compartment, remove the 2 fuel tank upper mounting strap nuts (1) and remove each of the mounting straps (3).
12. If installed, cut and dispose of the shipping strap.
13. With the assistance of another person, remove the fuel tank and filler neck assembly from the vehicle.
14. Remove and discard the hose clamps (1 and 3) from the fill pipe (2).
15. Remove the santoprene hose (3) off from around the filler neck flange molding and down along the fuel filler neck.
16. Disconnect the fuel tank vapor recirculation line (1) quick connect fitting. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-201043-S03534227022005102400000) .
17. Remove the santoprene hose (3) off from around the fuel tank cover flange.
18. Unclip the fuel tank to body wiring harness electrical connector from its mounting clip which connects onto the lower plastic fuel tank shell.
19. Wedge a large flat blade screwdriver in between the side skirting of each of the upper and lower plastic fuel tank shells (1 and 3), and pull each of the 8 clipping points free to separate and remove the upper plastic fuel tank shell as indicated.
20. Lift and remove the fuel tank (2) from the lower plastic fuel tank shell.

1. Lift and install the fuel tank (2) into the lower plastic fuel tank shell.
2. Install the upper plastic fuel tank shell.
3. Clip the fuel tank to body wiring harness electrical connector mounting clip onto the lower plastic fuel tank shell.
4. Install the santoprene hose (3) on and around the filler neck flange molding and down along the fuel filler neck.
5. Reconnect the fuel tank vapor recirculation line (1) quick connect fitting. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-201043-S03534227022005102400000) .
6. Install the santoprene hose (3) on and around the fuel tank cover flange.
7. Install new hose clamps (1 and 3) to the fill pipe (2).
8. With the assistance of another person, install the fuel tank and filler neck assembly to the vehicle.
9. Install each of the mounting straps (3), and fasten with the 2 fuel tank upper mounting strap nuts (1). Tighten: Tighten the fuel tank mounting strap upper fastening nut to 20 N.m (15 lb ft).
10. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-201059-S03425061632005102400000) in General Information.
11. Install the lower fuel tank mounting strap nuts (1). Tighten: Tighten the fuel tank mounting strap lower fastening nut to 40 N.m (30 lb ft).
12. Connect the fuel feed line quick connect fitting (1).
13. Connect the fuel tank to fuel feed line quick connect fitting (2). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-201043-S03534227022005102400000) .
14. Install the fuel tank vent line quick connect fitting (2). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-201043-S03534227022005102400000) .
15. Lower the vehicle.
16. Install the 3 nuts (1) securing the fuel filler neck to the filler pocket (4). Tighten: Tighten the fuel filler neck to filler pocket fastening nut to 5 N.m (44 lb in).
17. Install the fuel filler cap (3).
18. Connect the body wiring harness to fuel tank harness electrical connector (1).
19. Install the rear compartment support brace to gain access to the fuel tank. Refer to «Support Brace Replacement - Rear Compartment»(ref-201066-S16165695192005102400000) in Body Rear End.
20. Refill the fuel tank and check for leaks.

1. Remove the modular fuel sender assembly from the fuel tank. Refer to «Fuel Sender Assembly Replacement»(ref-201043-S26183717232005102400000) .
2. Use a flat blade driver to assist removal of the fuel level sender assembly harness connector from underneath the modular fuel pump and sender assembly cover.
3. Use a flat blade driver to assist removal of the fuel pump harness connector from underneath the modular fuel pump and sender assembly cover.
4. Press in the tang retaining the fuel pump connector on the fuel pump and filter assembly, then remove the connector.
5. Remove the modular fuel pump and sender assembly cover from the reservoir.
6. Remove the fuel pressure regulator.
7. Pry open both tangs securing the fuel outlet connector to the bottom of the motor and filter assembly, then remove the fuel outlet pipe from the motor and filter assembly.
8. Push the motor and filter assembly down the spring shafts and remove the circlip (only one shaft is fitted with a circlip) from the end of the shaft.
9. Clamp the protruding end of the modular fuel pump in a soft jawed vice to support the fuel filter and pump assembly in place. IMPORTANT: Do not over tighten the vice grips as this may damage the fuel pump.
10. Insert a pair of medium sized flat bladed screwdrivers through each of the service holes in the fuel filter assembly.
11. Firmly slide the blade between the fuel pump end cap and the internal fuel filter clips that hold the fuel pump in place.
12. Push the screwdrivers in far enough so that the internal fuel filter clips are deflected just free of each of the fuel pump end cap retainer shoulders.
13. Hold the screwdrivers in place with one hand, and move the fuel filter assembly in an upward direction to separate it from the fuel pump.
14. Remove the fuel pump assembly.
15. Remove the black ground wiring bridge from the fuel filter assembly.

1. Install the black ground wiring bridge to the fuel filter assembly.
2. Push the fuel pump assembly in the fuel filter housing, until it locks in place.
3. Push the motor and filter assembly down the spring shafts and install the circlip (only one shaft is fitted with a circlip) to the end of the shaft.
4. Install the fuel outlet connector to the bottom of the motor and filter assembly.
5. Install the fuel pressure regulator.
6. Install the modular fuel pump and sender assembly cover to the reservoir.
7. Install the fuel pump connector on the fuel pump and filter assembly.
8. Install the fuel pump harness connector to the modular fuel pump and sender assembly cover.
9. Install the fuel level sender assembly harness connector to the modular fuel pump and sender assembly cover.
10. Install the modular fuel sender assembly in the fuel tank. Refer to «Fuel Sender Assembly Replacement»(ref-201043-S26183717232005102400000) .

1. Remove the fuel tank assembly. Refer to «Fuel Tank Replacement»(ref-201043-S37798638172005102400000) .
2. Remove the modular fuel pump and sender assembly from the fuel tank. Refer to «Fuel Sender Assembly Replacement»(ref-201043-S26183717232005102400000) . IMPORTANT: Do not pull or lever the fuel tank pressure sensor out from the connector end as damage may occur to the sensor body.
3. Remove the fuel tank pressure sensor (2) from the sender assembly cover (1).

1. Install the fuel tank pressure sensor (2) to the sender assembly cover (1).
2. Install the modular fuel pump and sender assembly to the fuel tank. Refer to «Fuel Sender Assembly Replacement»(ref-201043-S26183717232005102400000) .
3. Install the fuel tank assembly. Refer to «Fuel Tank Replacement»(ref-201043-S37798638172005102400000) .

1. Remove the modular fuel sender assembly from the fuel tank. Refer to «Fuel Sender Assembly Replacement»(ref-201043-S26183717232005102400000) .
2. Use a flat-bladed driver to assist removal of the fuel level sender assembly harness connector from underneath the modular fuel pump and sender assembly cover.
3. Pry the tang open that holds the fuel sender assembly (1) to the side of the reservoir, then lift it OFF from the reservoir.

1. Install the fuel sender assembly (1) to the side of the reservoir.
2. Install the fuel level sender assembly harness connector to the modular fuel pump and sender assembly cover.
3. Install the modular fuel sender assembly to the fuel tank. Refer to «Fuel Sender Assembly Replacement»(ref-201043-S26183717232005102400000) .

1. Remove the fuel tank assembly. Refer to «Fuel Tank Replacement»(ref-201043-S37798638172005102400000) .
2. Loosen the fuel tank filler neck throat to fuel filler neck flexible hose hose-clamp (3).
3. Remove the filler neck hose (2) off from around the fuel tank filler neck throat (1).

1. Install the filler neck hose (2) on the fuel tank filler neck throat (1)
2. Install the fuel tank filler neck throat to fuel filler neck flexible hose hose-clamp (3).
3. Install the fuel tank assembly. Refer to «Fuel Tank Replacement»(ref-201043-S37798638172005102400000) .

1. Remove the fuel tank assembly. Refer to «Fuel Tank Replacement»(ref-201043-S37798638172005102400000) .
2. Disconnect the fuel tank pressure sensor connector (1), the fuel pump connector (2), and the EVAP vapor hose quick connector (3), from the modular fuel pump and sender assembly cover (4).
3. Remove the flanged nut securing the modular fuel pump and sender assembly ground terminal to the fuel tank flange stud, and remove the fuel tank wiring harness.
4. Using the J 45722 (2) and a half-inch breaker bar (1), remove the cover retainer lock ring (3) by turning in a counterclockwise direction. See «Special Tools»(ref-201043-S19962986522005102400000) .
5. Partially lift the modular fuel pump and sender assembly away from the fuel tank, taking care not to damage the fuel level sender assembly.
6. Disconnect the fuel tank evaporative emission (EVAP) vapor line quick connector from the underside of the modular fuel pump and sender assembly cover.
7. Insert hand into the fuel tank opening and disconnect the fuel feed line quick connector.
8. Remove the modular fuel pump and sender assembly.
9. Remove and discard the modular fuel pump and sender assembly to fuel tank seal.

1. Before installation into the fuel tank, check the fuel sender float position. Stand the assembly upright on a flat surface. Measure the distance between the middle of the fuel sender float and the flat surface. If required, the float position should be corrected, through careful adjustment of the float arm. Float Position: 7-14 mm.
2. Clean any dirt and foreign materials from the fuel tank seal recess and position a new seal in the recess.
3. Install the modular fuel pump and sender assembly into the fuel tank, taking care not to damage the fuel level sender float and arm in the process.
4. Insert hand into the fuel tank opening and connect the fuel feed line quick connector.
5. Connect the fuel tank EVAP vapor line quick connector from the underside of the modular fuel pump and sender assembly cover.
6. Ensure the locator in the cover engages in the slot in the tank opening.
7. Install the cover retainer lock ring. Use the half-inch breaker bar with J 45722 and rotate the retainer in a clockwise direction until the tangs are engaged. See «Special Tools»(ref-201043-S19962986522005102400000) .
8. Install the fuel tank wiring harness, and the flanged nut securing the modular fuel pump and sender assembly ground terminal to the fuel tank flange stud. Tighten: Tighten the flange nut to 7 N.m (62 lb in).
9. Install the fuel tank pressure sensor connector (1), the fuel pump connector (2), and the EVAP vapor hose quick connector (3) to the modular fuel pump and sender assembly cover (4).
10. Install the fuel tank assembly. Refer to «Fuel Tank Replacement»(ref-201043-S37798638172005102400000) .

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-201043-S21654027382005102400000) .
2. Loosen the fuel filler cap to relieve any vapor pressure.
3. Disconnect the negative battery cable.
4. Disconnect the engine compartment fuel feed pipe (1) at the fuel rail.
5. Cap the fuel pipe to prevent possible fuel system contamination.

1. Install the engine compartment fuel feed pipe (1) at the fuel rail.
2. Install the fuel filler cap.
3. Inspect for leaks.
4. Connect the negative battery cable. Turn ON the ignition for 2 seconds. Turn OFF the ignition for 2 seconds. Turn ON the ignition. Inspect for fuel leaks.
5. Install both engine sight shield covers. Refer to «Engine Sight Shield Replacement»(ref-201074-S21314046442005102400000) in Engine Mechanical.

1. Disconnect the fuel and evaporative emission (EVAP) lines at the engine compartment. Refer to «Fuel Hose/Pipes Replacement - Engine Compartment»(ref-201043-S07804276962005102400000) .
2. Disconnect the fuel and EVAP lines at the fuel tank. Refer to «Fuel Tank Replacement»(ref-201043-S37798638172005102400000) .
3. Remove the bolts (2) and the nuts (1) securing the stone guard.
4. Remove all the fuel line bracket pop rivets securing the fuel and EVAP pipes to the under body.
5. Remove the fuel and EVAP lines from the vehicle.

1. Install the fuel and EVAP lines to the vehicle.
2. Install the fuel line bracket pop rivets.
3. Install the bolts (2) and the nuts (1) to the stone guard.
4. Install the fuel and EVAP lines at the fuel tank. Refer to «Fuel Hose/Pipes Replacement - Engine Compartment»(ref-201043-S07804276962005102400000) .
5. Install the fuel and EVAP lines at the engine compartment. Refer to «Fuel Tank Replacement»(ref-201043-S37798638172005102400000) .
6. Inspect for leaks. Turn ON the ignition for 2 seconds. Turn OFF the ignition for 2 seconds. Turn ON the ignition. Inspect for fuel leaks.

1. Lubricate the new lower injector O-ring seals with clean engine oil.
2. Install the new O-ring seals on the spray tip end of each injector.
3. Install the fuel rail assembly to the intake manifold.
4. Apply a 0.5 mm (0.020 in) band of GM P/N 12345382 (Canadian P/N 10953489) threadlock or equivalent to the threads of the fuel rail bolts. NOTE: Refer to the Fastener Notice in Cautions and Notices.
5. Install the fuel rail attaching bolts (511, 512), ground strap (557). Tighten: Tighten the fuel rail attaching bolts to 10 N.m (89 lb in).
6. Connect the injector electrical connectors. Install each connector on the proper injector in order to ensure correct sequential injector firing order. Rotate the injectors as required in order to avoid stretching the wire harness.
7. Connect the electrical harness to the fuel rail brackets.
8. Connect the fuel feed hose to the fuel rail fuel pipe. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-201043-S03534227022005102400000) .
9. Connect the negative battery cable.
10. Inspect for leaks. Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.

1. Remove the fuel rail assembly. Refer to «Fuel Rail Assembly Replacement»(ref-201043-S28049850932005102400000) .
2. Disconnect the electrical connector (3) for the fuel injector (1).
3. Remove the retaining clip (4) for the fuel injector (1).
4. Remove the fuel injector (1) from the fuel rail (7).

1. Apply a small amount of clean motor oil to the O-rings (2) and (10), before installing the new fuel injector.
2. Install the fuel injector (1) in the fuel rail (7).
3. Install the retaining clips for the fuel injector (4).
4. Reconnect the electrical connector (3) for the fuel injector (1).
5. Install the fuel rail assembly (7). Refer to «Fuel Rail Assembly Replacement»(ref-201043-S28049850932005102400000) .
6. Inspect for leaks: Turn the ignition switch ON for 2 seconds. Turn the ignition switch OFF for 10 seconds. Turn the ignition switch ON. Inspect for fuel leaks.

1. Disconnect the electrical connector from the evaporative emission (EVAP) purge solenoid (1).
2. Disconnect the EVAP purge pipe (2) by squeezing the retaining clip and pulling the hose from the solenoid.
3. Disconnect the engine vacuum pipe (3) from the purge solenoid.
4. Remove the bolt (2) from the EVAP purge solenoid mounting bracket and remove the EVAP purge solenoid valve (1).

1. Install the bolt (2) to the EVAP purge solenoid mounting bracket and install the EVAP purge solenoid valve (1). Tighten: Tighten the bolt to 5 N.m (4 lb in).
2. Install the EVAP purge pipe (2) by squeezing the retaining clip and pulling the hose from the solenoid.
3. Install the engine vacuum pipe (3) from the purge solenoid.
4. Install the electrical connector from the EVAP purge solenoid (1).

1. Remove the right rear wheelhouse liner panel. Refer to «Wheelhouse Liner Panel Replacement - Rear»(ref-201066-S24724679922005102400000) in Body Rear End.
2. Compress the clamp (1) on the canister vent valve end of the canister vent hose (2), and slide the clamp back along the hose.
3. Rotate the canister vent hose back and forth, and pull to remove it from the canister vent valve (4).
4. Depress the locking tang and remove the wiring harness connector (3) from the canister vent valve.
5. Insert a thin blade screwdriver between the canister vent valve and the mounting bracket to release the retaining tang, and remove the canister vent valve.

1. Install the canister vent valve to the mounting bracket.
2. Connect the wiring harness connector (3) to the canister vent valve.
3. Install the canister vent hose.
4. Compress the clamp (1) and install on the canister vent valve end of the canister vent hose (2).
5. Install the right rear wheelhouse liner panel. Refer to «Wheelhouse Liner Panel Replacement - Rear»(ref-201066-S24724679922005102400000) in Body Rear End.

1. Loosen the fuel filler cap to relieve any vapor pressure.
2. Disconnect the negative battery cable.
3. Remove both engine sight shield covers. Refer to «Engine Sight Shield Replacement»(ref-201074-S21314046442005102400000) in Engine Mechanical.
4. Disconnect the EVAP purge pipe (2) by squeezing the retaining clip and pulling the hose from the solenoid.
5. Disconnect the engine vacuum pipe (3) from the purge solenoid.

1. Install the EVAP purge pipe (2) on the hose from the solenoid.
2. Install the engine vacuum pipe (3) on the purge solenoid.
3. Install the fuel filler cap.
4. Connect the negative battery cable.
5. Install both engine sight shield covers. Refer to «Engine Sight Shield Replacement»(ref-201074-S21314046442005102400000) in Engine Mechanical.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-201059-S03425061632005102400000) in General Information.
2. Disconnect the fuel tank vapor line (6) from the canister (2).
3. Disconnect the canister purge line (7) from the canister (2).
4. Remove the canister vent line (1) from the canister (2) by twisting and pulling it away from the canister.
5. Remove the canister retaining nut (4).
6. Remove the canister (3) from the attaching stud (2) and then slide the canister out of the retainer enclosed slots (5).

1. Install the canister (3) onto the retainer (5) and over the retaining stud (2).
2. Install the canister retaining nut (4), hand tighten only.
3. Push the canister in board as far as possible in the enclosed slots (5) of the retainer, and tighten the canister retaining nut to the specified torque. Tighten: Tighten the canister retaining nut to 6 N.m (53 lb in).
4. Install the canister vent line (1) onto the canister vent port (3).
5. Align the canister purge line quick connector (7) with the canister purge line port (5) and push the connector firmly onto the port.
6. Align the fuel tank vapor line quick connector (5) with the fuel tank vapor port (4) and push the connector firmly onto the port.

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

1. Install the ignition coil.
2. Install the ignition coil mounting bolts. Tighten: Tighten the ignition coil mounting bolts to 12 N.m (106 lb in).
3. Connect the spark plug wire at the ignition coil.
4. Connect the ignition coil harness connector.

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

1. Install the spark plug wires at the ignition coil.
2. Install the spark plug wire to each spark plug.
3. Inspect the wires for proper installation: Push sideways on each boot in order to inspect the seating. Reinstall any loose boot.

1. Remove the spark plug wires. Refer to «Spark Plug Wire Replacement»(ref-201043-S06832996822005102400000) .
2. Loosen each spark plug 1 or 2 turns.
3. Use a brush, or use compressed air in order to remove any dirt from the spark plugs.
4. Remove the spark plugs one at a time and place each plug in a tray marked with the corresponding cylinder numbers.

1. Inspect each spark plug gap. Adjust each plug as needed. Specification: Spark plug gap: 1.524 mm (0.060 in).
2. Hand start the spark plugs in the corresponding cylinders. NOTE: Refer to Fastener Notice in Cautions and Notices.
3. Tighten the spark plugs. Tighten: Tighten the 5.7 L engine spark plug on a NEW cylinder head to 20 N.m (15 lb ft). Tighten the 5.7 L engine spark plug on subsequent installations to 15 N.m (11 lb ft).
4. Install the spark plug wires. Refer to «Spark Plug Wire Replacement»(ref-201043-S06832996822005102400000) .

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-201059-S03425061632005102400000) in General Information.
2. Remove the starter. Refer to «Starter Motor Replacement»(ref-201045-S23262727732005102400000) in Engine Electrical.
3. Disconnect the crankshaft position (CKP) sensor electrical connector.
4. Remove the CKP sensor retaining bolt.
5. Remove the CKP sensor.

1. Install the CKP sensor.
2. Install the CKP sensor retaining bolt. Tighten: Tighten the CKP sensor to 25 N.m (18 lb ft).
3. Connect the CKP sensor electrical connector.
4. Install the starter. Refer to «Starter Motor Replacement»(ref-201045-S23262727732005102400000) in Engine Electrical.
5. Lower the vehicle.
6. Perform the CKP System Variation Learn Procedure. Refer to «CKP System Variation Learn Procedure»(ref-201043-S19765510982005102400000) .

1. Remove the generator bracket assembly. Refer to «Generator Bracket Replacement»(ref-201045-S37609942962005102400000) in Engine Electrical.
2. Disconnect the camshaft position (CMP) sensor electrical connector (1).
3. Remove the CMP sensor mounting bolt (1).
4. Remove the CMP sensor assembly (2, 3) from the engine front cover.

1. Install the CMP sensor assembly (2, 3) to the engine front cover.
2. Install the CMP sensor mounting bolt (1). Tighten: Tighten the camshaft position mounting bolts 25 N.m (18 lb ft).
3. Install the CMP sensor electrical connector (1).
4. Install the generator assembly. Refer to «Generator Bracket Replacement»(ref-201045-S37609942962005102400000) in Engine Electrical.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-201045-S04579536502005102400000) in Engine Electrical.
2. Remove the mounting bolt for the knock sensor (KS) 1.
3. Disconnect the electrical connector of the KS from the engine harness (3).
4. Remove the KS (2) from the engine block (4).

1. Reconnect the engine harness (3) and the KS (2) electrical connectors.
2. Position the KS 2 on the engine block (4).
3. Install the mounting bolt (1) for the KS 2.
4. Tighten the KS mounting bolt (1). Tighten: Tighten the KS mounting bolt to 20 N.m (15 lb ft).
5. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-201045-S04579536502005102400000) in Engine Electrical.

1. Remove 3 retainer screws securing the air cleaner upper body.
2. Remove air cleaner upper body and air cleaner filter assembly.

1. Reassemble the air cleaner element into the air cleaner upper body and place the upper body onto the lower air cleaner body.
2. Reinstall the 3 retaining screws securing the upper air cleaner body to the lower and tighten to the correct torque specification. Tighten: Tighten the air cleaner upper housing to 5 N.m (44 lb in).

1. Disconnect the wiring harness connector (2) to the Intake Air Temperature (IAT)/mass Air Flow (MAF) sensor (1).
2. Loosen the clamp securing the air intake duct to the throttle body (5), then loosen the clamp securing the MAF sensor to the air cleaner upper body (2).
3. Remove the duct together with the IAT/MAF sensor still installed.
4. Remove 3 retainer screws securing the air cleaner upper body.
5. Remove air cleaner upper body and air cleaner filter assembly.
6. Remove the 3 retainer screws (1) securing the air cleaner lower body to the fender inner panel insulators.
7. Remove the air cleaner air inlet duct (2) from lower body, then remove air cleaner lower body.

1. Install the air cleaner lower body onto the mounting insulators.
2. Install the air cleaner inlet duct (2) to the lower air cleaner lower body (3).
3. Install the retaining screws (1) and tighten to the correct torque specification. Tighten: Tighten the air cleaner lower housing to 10 N.m (89 lb in).
4. Install the air cleaner element (4) into the air cleaner upper body (2) and place the upper body onto the lower air cleaner body.
5. Install the 3 retaining screws (1) securing the upper air cleaner body to the lower and tighten to the correct torque specification. Tighten: Tighten the air cleaner upper housing to 5 N.m (44 lb in).
6. Install the intake air duct and IAT/MAF sensor to the throttle body and upper air cleaner body. Install and tighten both duct clamps to the specified torque. Tighten: Tighten the intake air duct clamp to 2 N.m (18 lb in).
7. Reconnect wiring harness connectors (2) to the IAT/MAF sensor (1).