Engine Controls - Removal & Installation: Other Pontiac Sunfire I

THROTTLE BODY

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE (CNG)»(ref-153402-S10765672692003040400000) under FUEL SYSTEMS (CNG) or «FUEL SYSTEM PRESSURE RELEASE (GASOLINE)»(ref-153402-S34229557402003040400000) under FUEL SYSTEMS (GASOLINE).
2. Disconnect negative battery cable.
3. Remove the air cleaner resonator.
4. Disconnect and mark harness connections and vacuum hoses from throttle body.
5. Disconnect the Idle Air Control (IAC) valve harness connector.
6. Disconnect the Throttle Position (TP) sensor harness connector.
7. Disconnect the vacuum hoses at the throttle body.
8. Disconnect the cruise control cable (2) from the throttle body (3) and accelerator bracket (1). (Scheme 43) Remove the accelerator cable bracket.
9. Disconnect the accelerator control cable (3) from the throttle body (4) and accelerator bracket (1). (Scheme 44)
10. Remove the 2 accelerator bracket nuts (3). (Scheme 45)
11. Remove the accelerator bracket (2) from the throttle body (1). (Scheme 45)
12. Remove the throttle body attaching bolts and studs (1). (Scheme 46)
13. Remove the throttle body (4) from the intake manifold.
14. Tighten the throttle body attaching bolts and studs, and accelerator cable bracket nuts to test the accelerator movement by depressing the pedal to the floor and releasing the pedal.

1. Check the throttle body gasket and replace if necessary.
2. Install the throttle body to the intake manifold.
3. Install the throttle body attaching bolts and studs (5). Tighten the throttle body attaching bolts and studs to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S01137901832003040400000).
4. Install the accelerator bracket (2) on the throttle body (1). (Scheme 45) Tighten the accelerator bracket nuts to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S01137901832003040400000).
5. Connect the accelerator control cable (3) to the throttle body (4) and accelerator bracket (1). (Scheme 45)
6. Connect the cruise control cable (2) from the throttle body (3) and accelerator bracket (1). (Scheme 44)
7. Connect the vacuum hoses to the throttle body.
8. Connect the TP sensor harness connector.
9. Connect the IAC valve harness connector.
10. Install the air cleaner resonator.
11. Connect the negative battery cable. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
12. Test the accelerator movement by depressing the pedal to the floor and releasing the pedal.

COMPUTERIZED ENGINE CONTROLS

Fuel Injection Control Module (FICM) is located left of the radiator support behind fascia.

1. Disconnect negative battery cable.
2. Remove the Front Bumper Fascia.
3. Disconnect the FICM harness connector. (Scheme 24)
4. Remove the 4 FICM mounting bolts.
5. Remove the FICM from the vehicle. Perform the following steps only if removal of the FICM Mounting Bracket is desired.
6. Remove the hood close-out filler panel (1) push-pin retainers (2). (Scheme 25)
7. Disable the SIR system. See appropriate AIR BAG RESTRAINT SYSTEMS article in RESTRAINTS.
8. Disconnect the SIR forward discriminating sensor connector.
9. Remove the upper hood latch support bolts and upper radiator mounting bolts and brackets. (Scheme 26)
10. Angle the radiator assembly towards the front of the vehicle to allow for FICM bracket bolt removal.
11. Remove the FICM mounting bracket bolts and the support plate while holding the radiator in a forward position. (Scheme 27)
12. Remove the FICM mounting bracket from the vehicle.

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Note. Proceed to step 8 , if installation of the FICM mounting bracket is not required.

1. Install the FICM mounting bracket bolts through the support plate while holding the radiator in a forward position. (Scheme 27)
2. Loosely install both of the FICM mounting bracket bolts into the FICM mounting bracket. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
3. Install the radiator upper mounting brackets and bolts. (Scheme 26) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
4. Install the upper hood latch support bolts. (Scheme 25) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
5. Connect the SIR forward discriminating sensor connector.
6. Enable the SIR system. See appropriate AIR BAG RESTRAINT SYSTEMS article in RESTRAINTS.
7. Install the hood close-out filler panel. Install the hood close-out filler panel push-pin retainers. (Scheme 25)
8. Loosely install all of the FICM mounting bolts while ensuring that the FICM rubber isolators and spacers remain in position. (Scheme 28) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
9. Connect the FICM connector. (Scheme 24)
10. Install the Front Bumper Fascia.
11. Connect the negative battery cable. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).

Scheme 28

POWERTRAIN CONTROL MODULE

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

PCM is located on bracket, to left of right front strut tower. (Scheme 29)

1. Turn ignition switch to OFF position. Disconnect negative battery cable.
2. Push down the locking tab and pull up on the release lever and disconnect the PCM harness connectors.
3. Press the PCM retaining tab.
4. Lift the PCM from the PCM bracket.

Scheme 29

1. Remove the new PCM from the packaging and check the service number to verify the number is the same number, or an updated number, as the faulty PCM.
2. Push the PCM into the PCM bracket. The retaining tab will lock in place.
3. Install the PCM harness connectors and lock down the release levers.
4. Connect the negative battery cable. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
5. Program the PCM. See «PROGRAMMING»(ref-153402-S22819534202003090300000)

PROGRAMMING

Note. DO NOT program an existing PCM with the identical software/calibration package. This procedure is not a short cut to correct a driveability condition. This is an ineffective repair. A PCM should only be programmed when a service procedure instructs you to replace the PCM. The service part PCM does not contain operating software or calibrations or General Motors Corporation releases an updated software/calibration package.

After replacing Powertrain Control Module (PCM) or if program needs to be updated, refer to latest Techline® information on PCM reprogramming. PCM can only be programmed using Tech 2 and Techline® terminal, or by using a personal computer equipped with the current service programming system software installed.

SERVICE PROGRAMMING SYSTEM

After replacing PCM or if program needs to be updated, refer to latest Techline information on PCM reprogramming. Before programming a PCM, the following must be observed, or PCM damage may occur

1. The Tech 2 and the terminal must have the latest software.
2. The vehicle battery must be fully charged. The battery voltage should be 12-14 volts.
3. The Tech 2 and the terminal cable connections must be secure.
4. A battery charger must NOT be connected to the battery when programming a PCM.

After reprogramming, perform and

PROGRAMMING THEFT DETERRENT SYSTEM COMPONENTS

Service Programming Methods

The 4 methods of programming a PCM and the proper tools for each method are as follows

1. Remote Programming. See «SERVICE PROGRAMMING SYSTEM REMOTE PROCEDURE»(ref-153402-S31328452232003090300000) .
2. Pass Thru Programming. See «SERVICE PROGRAMMING SYSTEM PASS-THRU PROCEDURE»(ref-153402-S37634394562003090300000) .
3. Off-Board Remote Programming, vehicle NOT available. See «SERVICE PROGRAMMING SYSTEM OFF BOARD REMOTE PROCEDURE»(ref-153402-S03629060332003090300000) .
4. Off-Board Pass Thru Programming. See «SERVICE PROGRAMMING SYSTEM OFF BOARD PASS-THRU PROCEDURE»(ref-153402-S36612320792003090300000) .

All 4 methods may not be available for every vehicle.

SERVICE PROGRAMMING SYSTEM REMOTE PROCEDURE

The Remote Service Programming System (SPS) method is a three-step process that involves the following procedures

1. Connecting the Tech 2 to the vehicle and obtaining the information from the module.
2. Connecting the Tech 2 to the terminal and downloading a new calibration file from the terminal into the Tech 2 memory.
3. Reconnecting the Tech 2 to the vehicle and uploading the new calibration file into the module.

Remote Procedure

Note. Ensure the PCM is installed in the vehicle and the battery is fully charged before programming.

1. Connect the Tech 2 to the vehicle and obtain the module information using the following procedure: Connect the Tech 2 to the vehicle Data Link Connector (DLC), with the engine and the Tech 2 OFF. (Scheme 30) Turn ON the Tech 2. Press Enter at the title screen. Turn ignition switch to RUN position, engine OFF. Select SERVICE PROGRAMMING SYSTEM at the Main Menu. NOTE: Select REQUEST INFO AGAIN if a vehicle identification number (VIN) was previously stored in the Tech 2. Select REQUEST INFO. Enter the vehicle description by following the on-screen instructions. Turn all accessories OFF and select CONTINUE. Select NO and write down the VIN if the VIN is incorrect. Verify that the correct VIN is entered on the Tech 2 and select YES.
2. Turn OFF the Tech 2.
3. Disconnect the Tech 2 from the vehicle.
4. Turn ignition switch to OFF position.
5. Transfer the data from the terminal to the Tech 2 using the following procedure: Connect the Tech 2 to the terminal. (Scheme 31) NOTE: The Techline Information System (TIS) supports service programming with the Tech 2 scan tool only. Launch the TIS application at the terminal. Select the SERVICE PROGRAMMING SYSTEM at the main screen. Highlight the following information on the SELECT DIAGNOSTIC TOOL and PROGRAMMING PROCESS SCREEN: Select Diagnostic Tool - Select Tech 2. Select Programming Process - Identify whether an existing module is being reprogrammed or a module is being replaced with a new one. Select ECU Location - Select vehicle. Select NEXT. Verify the connections and select NEXT. NOTE: You may receive a message stating that the PCM could be a service PCM if you selected NO to the VIN being correct. Click OK. Verify the VIN and select Next. Select the appropriate controller for the vehicle being serviced. NOTE: When selecting the Vehicle Configuration Index (VCI) programming type, a valid VCI number for the vehicle must be entered. This number may be obtained from the Techline Customer Support. Select the type of programming to be performed from the following categories: Normal - Used for updating an existing calibration or programming a new controller. Vehicle Configuration Index (VCI) - Used for updating an existing controller or programming a new controller for newer vehicles whose VINs are not yet in the database. Reconfigure - Used to reconfigure a vehicle for changes in tire size and axle ratios. Select NEXT. NOTE: Refer to Service bulletins before service programming is performed if the bulletins are listed along with the calibration files. Select the appropriate calibration file for the vehicle being serviced. Select NEXT. NOTE: Select CANCEL if you receive a message stating that the calibration selected is already the current calibration in the PCM and reprogramming with the same download is not allowed. Verify your selection on the Summary screen. Select NEXT.
6. Perform the CRANKSHAFT POSITION VARIATION RELEARN PROCEDURE using the SPECIAL FUNCTIONS feature, if applicable. See «CKP SYSTEM VARIATION LEARN PROCEDURE»(ref-153402-S37836965312003090300000).
7. Close the application and return to the TIS application Selection screen after the download is complete.
8. Turn OFF the Tech 2.
9. Disconnect the Tech 2 from the terminal.
10. Transfer the data from the Tech 2 to the PCM using the following procedure: Turn OFF the ignition. Turn OFF the Tech 2. Disconnect the Tech 2 from the vehicle.

Scheme 30

Scheme 31

Verifying Reprogramming

Note. Some vehicles will require that Idle Learn, TP Learn, Theft Deterrent Relearn, or Crankshaft Variation Learn procedures be performed after programming. Consult the appropriate service information for these procedures.

Verify the PCM programming was successful using the following procedure

1. Turn OFF the ignition for 30 seconds.
2. Start the engine.
3. Repeat the SPS procedure if the vehicle does not start or starts but runs rough.

SERVICE PROGRAMMING SYSTEM PASS-THRU PROCEDURE

Note. The Techline Information System (TIS) supports service programming with the Tech 2™ scan tool only.

Pass-Thru programming allows the scan tool to remain connected to the terminal and to the vehicle throughout the programming process. The vehicle must be in close proximity to the terminal while using Pass-Thru.

Performing The Pass-Thru Procedure

1. Launch the TIS application at the terminal.
2. Select the SERVICE PROGRAMMING SYSTEM.
3. Highlight the following information on the Select Diagnostic Tool Programming Process screen: Select Diagnostic Tool - Select PASS-THRU. Select Programming - Identify whether an existing module is being reprogrammed or a module is being replaced with a new one. Select ECU Location - Select vehicle.
4. Select NEXT.
5. Complete all terminal-directed data on the PREPARING FOR COMMUNICATION/DETERMINE VEHICLE screen until NEXT is highlighted.
6. Select NEXT.
7. Follow the instructions on the PREPARING FOR COMMUNICATION screen.
8. Select NEXT.
9. Verify the VIN on the VALIDATE VEHICLE IDENTIFICATION NUMBER screen.
10. Select NEXT.
11. If an option screen appears, verify the vehicle configuration and/or RPO information.
12. Select Next.
13. Highlight the appropriate PCM and programming type on the Supported Controllers screen.
14. Select Next.
15. Select the proper calibrations on the Calibration Selection screen.
16. Ensure all the folder tabs have a green check mark.
17. Select NEXT.
18. Verify the current calibrations with the selected calibrations.
19. Select NEXT.
20. The TRANSFER DATA screen will appear until the progress bar reaches 100 percent. This may take up to 30 minutes.
21. Complete all of the terminal-directed data on the Programming Complete screen.
22. Turn OFF the Tech 2.
23. Disconnect the Tech 2™ from the vehicle.

SERVICE PROGRAMMING SYSTEM OFF BOARD REMOTE PROCEDURE

Note. Ensure the Tech 2 and the terminal are both equipped with the latest software before performing SPS.

The Off-Board Programming Adapter Kit (J 41207-C) is required when a module must be programmed without having the vehicle present. The adapter allows the module to be turned ON and communicate with the scan tool.

Performing the Off Board Remote Procedure

1. Obtain the Vehicle Identification Number (VIN) of the vehicle for which the module is being programmed.
2. Launch the TIS application at the terminal.
3. Select the SERVICE PROGRAMMING SYSTEM.
4. Highlight the following information on the Select Diagnostic Tool and Programming Process screen: Select Diagnostic Tool - Select Tech 2. Select Programming Process - Identify whether an existing module is being reprogrammed or replaced with a new one. Select ECU location - Select Off-Board Programming Adapter.
5. Select NEXT.
6. Follow the directions on the Preparing for Communication screen for connecting the following components: The PCM. The Off-Board Programming Adapter (OBPA). Refer to the TIS users guide for a listing of the OBPA. The Tech 2. (Scheme 32)
7. Select the SERVICE PROGRAMMING REQUEST INFORMATION function on the Tech 2.
8. Follow the Tech 2 instructions to obtain the module data and security information.
9. After the Tech 2 has received the data from the module, exit the REQUEST INFO mode.
10. Disconnect the Tech 2 from the OBPA.
11. Turn OFF the Tech 2.
12. Connect the Tech 2 to the terminal. (Scheme 31)
13. Turn ON the Tech 2.
14. Select Next at the terminal after the Tech 2 start-up screen appears.
15. Enter the VIN of the vehicle that will be receiving the NEW PCM.
16. Select NEXT.
17. Select the type of programming to be performed from the following categories: Normal - Used for updating an existing calibration or programming a new controller. Vehicle Configuration Index - Used for updating an existing controller or programming a new controller for newer vehicles whose VINs are not yet in the database. Reconfigure - Used to reconfigure a vehicle for changes in tire size and axle ratios.
18. Select NEXT.
19. Select a calibration on the CALIBRATION SELECTION screen, if necessary.
20. Ensure all the desired folder tabs have a Green check mark.
21. Select NEXT.
22. Verify the current and the selected calibration of the PCM on the summary screen.
23. Select NEXT.
24. Select OK.
25. On model year 1996 and newer controllers, a Crankshaft Position (CKP) relearn procedure box may appear. Select OK. See «CKP SYSTEM VARIATION LEARN PROCEDURE»(ref-153402-S37836965312003090300000).
26. Follow the on-screen instructions, if any, when the PROGRAM CONTROLLER/PROGRAMMING COMPLETE screen appears.
27. Select CLOSE.
28. Turn OFF the Tech 2.
29. Disconnect the Tech 2 from the terminal.
30. Connect the Tech 2 to the OBPA.
31. Turn ON the Tech 2.
32. Select ENTER at the title screen.
33. Select the SERVICE PROGRAMMING SYSTEM at the Main Menu.
34. Select the Program ECU function.
35. Select CONTINUE.
36. Follow the on-screen instructions.
37. Select CONTINUE.
38. Select Exit when the programming is complete.
39. Turn OFF the OBPA.
40. Turn OFF the Tech 2. Wait 30 seconds after the OBPA is turned OFF before disconnecting the PCM.
41. Disconnect the OBPA from the Tech 2 and the PCM.

Scheme 32

SERVICE PROGRAMMING SYSTEM OFF BOARD PASS-THRU PROCEDURE

Note. The Techline Information System (TIS) supports service programming with the Tech 2 scan tool only.

Note. Ensure the Tech 2 and the terminal are both equipped with the latest software before performing SPS.

The Off-Board Programming Adapter Kit (J 41207-C) is required when a module must be programmed without having the vehicle present. The adapter allows the module to be turned ON and communicate with the Tech 2.

Performing The Off Board Pass-Thru Procedure

1. Launch the Techline Information System (TIS) application in the terminal.
2. Select the SERVICE PROGRAMMING SYSTEM.
3. Highlight the following information on the Select Diagnostic Tool and Programming Process Screen: Select Diagnostic Tool - Select PASS-THRU. Select Programming Process - Identify whether an existing module is being reprogrammed, or a module is being replaced with a new one. Select ECU location - Select Off-Board Programming Adapter.
4. Select NEXT.
5. Complete all terminal-directed data at the PREPARING FOR COMMUNICATION/DETERMINE VEHICLE screen until NEXT is highlighted. (Scheme 32)
6. Select NEXT.
7. Follow the on-screen instructions for connecting the following components: The PCM. The Off-Board Programming Adapter (OBPA). Refer to the TIS Users Guide for a listing of OBPA. The Tech 2.
8. Select NEXT.
9. Pass-Thru displays the VIN stored in the PCM. If a new PCM is being programmed, enter the correct VIN of the vehicle.
10. Select NEXT.
11. Select the appropriate options if the OPTIONS screen appears.
12. Select NEXT.
13. Select the type of programming to be performed from the following categories: Normal - Used for updating an existing calibration or programming a new controller. Vehicle Configuration Index - Used for updating an existing controller or programming a new controller for newer vehicles whose VINs are not yet in the database. Reconfigure - Used to reconfigure a vehicle for changes in tire size and axle ratios.
14. Select NEXT.
15. Select a calibration selection on the Calibration Selection screen, if necessary.
16. Ensure all the desired calibration folder tabs have a green check mark.
17. Select NEXT.
18. Verify the current and selected calibration of the PCM on the Summary screen.
19. Select NEXT.
20. Select OK.
21. Select OK.
22. When programming is complete, a PROGRAM CONTROLLER/PROGRAMMING COMPLETE screen appears. Follow the on-screen instructions, if any.
23. Select CLOSE.
24. Turn OFF the OBPA.
25. Turn OFF the scan tool.
26. Disconnect the OBPA from the Tech 2 and the PCM.

CKP SYSTEM VARIATION LEARN PROCEDURE

1. Connect scan tool to DLC.
2. Monitor the Powertrain Control Module (PCM) for DTCs using scan tool. If other DTCs are set, except DTCs P1336, refer to «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-153397-S21975802792003040400000) under SELF-DIAGNOSTICS SYSTEM in SELF-DIAGNOSTICS - 2.2L ALERO, CAVALIER, GRAND AM & SUNFIRE - GASOLINE article for the applicable DTC that set.
3. Select the crankshaft position variation learn procedure using the scan tool.
4. Observe the fuel cut-off specifications for that engine.
5. The scan tool instructs you to perform the following: Accelerate to Wide Open Throttle (WOT). Release when the fuel cut-off occurs. Engine should not accelerate beyond calibrated RPM value. Release throttle immediately if value is exceeded. Block drive wheels. Set parking brake. DO NOT apply brake pedal. Cycle the ignition switch from OFF to ON position. Apply and hold the brake pedal. Start and idle engine. Turn A/C OFF. Vehicle must remain in Park or Neutral. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft Position Sensors Activity - If there is a CKP sensor condition, refer to the applicable DTC that set. Camshaft Position Sensor Activity - If there is a CMP sensor condition, refer to the applicable DTC that set. Engine Coolant Temperature - If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature.
6. Enable the crankshaft position system variation learn procedure using the scan tool.
7. Accelerate to WOT.
8. Release when the fuel cut-off occurs.
9. The scan tool displays LEARN STATUS: LEARNED THIS IGNITION. If the scan tool indicates that DTC P1336 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P1336 failed or did not run, go to «DTC P1336: CRANKSHAFT POSITION SYSTEM VARIATION NOT LEARNED»(ref-153397-S41211973582003040400000) under DIAGNOSTIC TESTS in SELF-DIAGNOSTICS - 2.2L ALERO, CAVALIER, GRAND AM & SUNFIRE - GASOLINE article. If any other DTCs set, go to «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-153397-S21975802792003040400000) under SELF-DIAGNOSTICS SYSTEM in SELF-DIAGNOSTICS - 2.2L ALERO, CAVALIER, GRAND AM & SUNFIRE - GASOLINE article for the applicable DTC that set.
10. Turn ignition switch to OFF position for 30 seconds after the learn procedure is completed successfully.

PROGRAMMING THEFT DETERRENT SYSTEM COMPONENTS

Note. Due to component variability, the Vehicle Theft Deterrent (VTD) system must have the learn procedure performed regardless, if vehicle starts on the first ignition cycle after a VTD repair. All codes in the theft deterrent module must be cleared for a relearn.

Note. The BCM must be programmed with proper RPO configurations before performing learn procedures. If replacing BCM with a GM Service Parts Operations (SPO) replacement part, the module will learn Passlock™ sensor data code immediately. The existing PCM however, must learn the new fuel continue password when BCM is replaced.

Note. If replacing a PCM with a replacement part, after programming, these modules will learn incoming fuel continue password immediately upon receipt of a password message. Once a password message is received and a password is learned, a learn procedure must be performed to change this password again. A PCM which has been previously installed in another vehicle will have learned the other vehicle's fuel continue password and will require a learn procedure after programming to learn current vehicle's password.

Use these procedures after replacing

1. Passlock™ Sensor
2. BCM
3. PCM

10 Minute Learn Procedure

1. Turn ignition switch to RUN position, engine OFF.
2. Attempt to start the engine, then release the key to ON (vehicle will not start).
3. Observe the SECURITY telltale, after approximately 10 minutes the telltale will turn OFF.
4. Turn OFF the ignition, and wait 5 seconds.
5. The vehicle is now ready to relearn the Passlock™ Sensor Data Code and/or passwords on the next ignition switch transition from OFF to CRANK.
6. Start the engine. The vehicle has now learned the Passlock™ Sensor Data Code and/or password.
7. Using a scan tool, clear any DTCs if needed. History DTCs will self clear after 100 ignition cycles.

Crankshaft Position (CKP) sensor is located on the right front of engine, above starter.

1. Disconnect the battery.
2. Raise and support the vehicle.
3. Remove the front air deflector, if applicable.
4. Remove the starter.
5. Disconnect the Crankshaft Position (CKP) sensor harness connector.
6. Remove the CKP sensor bolt and CKP sensor. (Scheme 33)

Scheme 33

1. Check the CKP sensor "O" ring and lubricate with a mineral based grease.
2. Carefully insert the CKP sensor into the block. (Scheme 33)
3. Install the CKP sensor bolt. Tighten the CKP sensor bolt to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
4. Reconnect the CKP sensor harness connector.
5. Reinstall the starter.
6. Reinstall the front air deflector, if applicable.
7. Lower the vehicle.
8. Connect the negative battery cable. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
9. Perform the CKP system Variation Learn Procedure. See «CKP SYSTEM VARIATION LEARN PROCEDURE»(ref-153402-S37836965312003090300000).

ENGINE COOLANT TEMPERATURE SENSOR

Engine Coolant Temperature (ECT) sensor is located at the right rear of engine, between heater hoses.

1. Turn ignition switch to OFF position.
2. Drain the coolant system to below the ECT sensor.
3. Disconnect the ECT sensor harness connector.
4. Carefully remove the ECT sensor. (Scheme 34)
5. To install, reverse removal procedures. Coat the threads using sealer (P/N 9985253), or equivalent. Tighten ECT to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000). Refill the engine cooling system.

Scheme 34

1. Disable SIR system. See appropriate AIR BAG RESTRAINT SYSTEMS article in RESTRAINTS. Remove Instrument Panel (IP) trim pad. (Scheme 35) Remove defroster grille screw. Using a flat-bladed tool, remove defroster grille from IP trim pad. Remove IP outer trim cover screws. Remove IP outer trim covers. Open glove compartment and remove right IP trim plate bezel. Remove IP trim pad screws and remove IP trim pad from IP carrier.
2. Remove screws from IP trim plate and remove IP accessory trim plate by pulling rearward to disengage retainers. Disconnect harness connectors from trim plate. Unsnap fuel gauge select switch from trim plate. (Scheme 36) To install, reverse removal procedure.

Scheme 35

Scheme 36

FUEL LEVEL SENSOR

Note. Fuel level sensor is located in fuel tank and is integral with fuel sender assembly.

Note. Numbers in parenthesis correspond to numbered components in referenced illustrations.

1. Remove the fuel sender assembly. See «FUEL SENDER ASSEMBLY»(ref-153402-S21570549432003040400000) under FUEL SYSTEMS (GASOLINE).
2. Remove the fuel pump and fuel level sensor harness retaining clip at the top of the fuel sender assembly.
3. Disconnect the fuel pump and fuel level sensor harness connector.
4. Depress the 3 tabs (1) securing upper fuel reservoir and slide upward until free of lower reservoir (2). (Scheme 37)
5. Depress the tab on the fuel level sensor (1) while sliding up and out of the housing. (Scheme 38)
6. Remove the retaining clip from the harness connector.
7. Remove the fuel level sensor wires from the connector, taking care to note the location of the wires.

Scheme 37

Scheme 38

1. Install the fuel level sensor (1) by sliding the sensor down in the housing.
2. Slide the upper reservoir into the lower reservoir (2).
3. Connect the 2 wires into the connector and lock the connector with the retaining clip.
4. Connect the fuel pump and fuel level sensor harness connector and lock the connector with the retaining clip.
5. Install the fuel sender assembly. See «FUEL SENDER ASSEMBLY»(ref-153402-S21570549432003040400000) .

FUEL TANK PRESSURE SENSOR (CNG)

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE (CNG)»(ref-153402-S10765672692003040400000) under FUEL SYSTEMS (CNG).
2. Disconnect the negative battery cable.
3. Remove spare tire cover. Remove jack and tool kit. Remove spare tire. Remove 4 tank cover bolts. Remove tank cover. (Scheme 75)
4. Remove the tank vent boot cover nuts and the cover. (Scheme 76)
5. Disconnect the Fuel Tank Pressure (FTP) sensor harness connector. (Scheme 39)
6. Remove the FTP sensor from the High Pressure Lock-Off (HPL) solenoid.

Scheme 39

1. Install the FTP sensor (1) with a NEW "O" ring. Lubricate the "O" ring with petroleum jelly, or equivalent. Tighten the FTP sensor to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
2. Connect the FTP sensor harness connector.
3. Connect the HPL power harness connector.
4. Connect the negative battery cable. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
5. Start the vehicle. Check for CNG fuel leaks at each serviced fitting using the Combustible Gas Detector (J 45878).
6. Install the tank vent boot cover and the nuts. Tighten the tank vent boot cover nuts to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
7. Install the fuel tank cover. Tighten the fuel tank cover nuts to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .

Fuel Tank Pressure (FTP) sensor is located on fuel sender assembly. (Scheme 40)

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE (GASOLINE)»(ref-153402-S34229557402003040400000) under FUEL SYSTEMS (GASOLINE).
2. Disconnect negative battery cable.
3. Remove fuel tank. See «FUEL TANK (GASOLINE)»(ref-153402-S19914623502003040400000) under FUEL SYSTEMS (GASOLINE).
4. Disconnect FTP sensor harness connector.
5. Remove FTP sensor.
6. To install, reverse removal procedure.
7. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
8. Check for leaks by using the following procedure: Turn ignition switch to RUN position for 2 seconds. Turn ignition switch to OFF position for 10 seconds. Turn ignition switch to RUN position. Check for fuel leaks.

Scheme 40

FUEL TANK TEMPERATURE SENSOR

Note. Fuel Tank Temperature (FTT) sensor is a thermistor mounted inside the High Pressure Lock-Off (HPL) and is not serviceable separately from the HPL. See HIGH PRESSURE LOCK-OFF SOLENOID under RELAYS & SOLENOIDS.

INTAKE AIR TEMPERATURE SENSOR

IAT sensor is located in air cleaner resonator. (Scheme 41) Turn ignition switch to OFF position. Disconnect negative battery cable. Disconnect the air cleaner duct from the air cleaner resonator. Disconnect the IAT sensor harness connector. While twisting the IAT sensor, pull the sensor from the air cleaner resonator. To install, reverse removal procedure. Tighten air cleaner duct-to-air cleaner resonator clamp to specification. See TORQUE SPECIFICATIONS.

Scheme 41

The Knock Sensor (KS) is located in engine block, near starter. (Scheme 42)

1. Turn ignition switch to OFF position. Disconnect negative battery cable.
2. Remove the starter.
3. Disconnect the KS harness connector.
4. Remove the KS retaining bolt.
5. Remove the KS.

Scheme 42

1. Ensure the KS threaded surfaces are clean before installation.
2. Install the knock sensor. Tighten the knock sensor retaining bolt to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
3. Connect the knock sensor harness connector.
4. Install the starter.
5. Connect the negative battery cable. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .

Note. Numbers in parenthesis correspond to numbered components in referenced illustration.

Manifold Absolute Pressure (MAP) sensor is located on the intake manifold.

1. Turn ignition switch to OFF position.
2. Disconnect negative battery cable. Remove the air cleaner outlet resonator.
3. Disconnect the cruise control cable (2) from the throttle body (3) and accelerator bracket (1). (Scheme 43) Remove the accelerator cable bracket.
4. Disconnect the accelerator control cable (3) from the throttle body (4) and accelerator bracket (1). (Scheme 44)
5. Remove the 2 accelerator bracket nuts (3). (Scheme 45)
6. Remove the accelerator bracket (2) from the throttle body (1). (Scheme 45)
7. Disconnect the Manifold Absolute Pressure (MAP) sensor harness connector.
8. Remove the MAP sensor (2) from the intake manifold. (Scheme 46)
9. Check the seal for damage. If the MAP sensor seal is damaged, the MAP sensor must be replaced.

Scheme 43

Scheme 44

Scheme 45

Scheme 46

1. Install the MAP sensor (2) into the intake manifold. (Scheme 46)
2. Connect the MAP sensor harness connector.
3. Install the accelerator bracket (2) on the throttle body (1). (Scheme 45) Tighten the accelerator bracket nuts to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S01137901832003040400000).
4. Connect the accelerator control cable (3) to the throttle body (4) and accelerator bracket (1). (Scheme 45)
5. Connect the cruise control cable (2) from the throttle body (3) and accelerator bracket (1). (Scheme 44)
6. Install the air cleaner outlet resonator.
7. Connect the negative battery cable. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).

OXYGEN SENSORS

Note. The oxygen sensor may be difficult to remove when the engine temperature is less than 120°F (48°C).

HIGH PRESSURE LOCK-OFF SOLENOID

Note. Numbers in parenthesis correspond to numbered components in referenced illustrations.

1. Relieve the CNG fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE (CNG)»(ref-153402-S10765672692003040400000) under FUEL SYSTEMS (CNG).
2. Disconnect the negative battery cable.
3. Remove spare tire cover. Remove jack and tool kit. Remove spare tire. Remove 4 tank cover bolts. Remove the tank cover. (Scheme 75)
4. Vent the fuel pressure from the tank. See «FUEL TANK VENTING»(ref-153402-S00524229582003040400000) under FUEL SYSTEMS (CNG)..
5. Remove the vent hose (6) from the High Pressure Lock-Off (HPL) solenoid. (Scheme 80)
6. Remove the fuel line fittings and discard the "O" rings.
7. Remove the manual vent tool.
8. Disconnect the Pressure Relief Device (PRD) outlet line (4).
9. Remove the PRD line fitting (4).
10. Remove the HPL harness connector bracket stand-offs.
11. Using the HPL Crowfoot (J 43602) removal tool, or equivalent, loosen the HPL. (Scheme 47)
12. Remove the HPL from the CNG fuel tank and discard the HPL and "O" ring.
13. If fuel contamination is suspected remove and clean the CNG tank prior to installing the new HPL. See «FUEL TANK»(ref-153402-S11834719592003040400000) under FUEL SYSTEMS (CNG). See «FUEL TANK CLEANING (CNG)»(ref-153404-S00624762972003062400000) under FUEL SYSTEMS (CNG) in SYSTEM & COMPONENT TESTS - 2.2L ALERO, CAVALIER, GRAND AM & SUNFIRE article.

Scheme 47

1. Install the new "O" ring on the HPL.
2. Lubricate the "O" ring with petroleum jelly.
3. Ensure that the "O" ring mating surface of the tank is clean and free of debris or damage.
4. Install the HPL. Tighten the HPL to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
5. Install the HPL fill line fitting (4) with a NEW "O" ring. Lubricate the "O" ring with petroleum jelly, or equivalent. The fill line fitting has the larger thread diameter to accept the fill line. Tighten the fitting to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
6. Install the HPL outlet fitting (8) with a NEW "O" ring. Lubricate the "O" ring with petroleum jelly, or equivalent. Tighten the fitting to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
7. Install the HPL PRD line fitting (6) with a NEW "O" ring. Lubricate the "O" ring with petroleum jelly, or equivalent. Tighten the fitting to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
8. Ensure that the lines are properly oriented to the HPL fittings. It may be necessary to rotate the CNG tank in the mounting brackets to obtain the proper alignment. See «FUEL TANK»(ref-153402-S11834719592003040400000) for the steps necessary to loosen the tank straps and rotate the tank.
9. Connect the fuel outlet line to the HPL fitting (1) with a NEW "O" ring face seal. Lubricate the "O" ring face seal using petroleum jelly, or equivalent. Tighten the fitting to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
10. Install the Fuel Tank Pressure (FTP) sensor (2) with a NEW "O" ring. Lubricate the "O" ring with petroleum jelly, or equivalent. Tighten the sensor to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
11. Connect the PRD line to the HPL fitting (4) with a NEW "O" ring face seal. Lubricate the "O" ring face seal using petroleum jelly, or equivalent. Tighten the fitting to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
12. Install the HPL harness connector stand-offs. Tighten the stand-offs to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
13. Connect the fill line to the HPL fitting with a NEW "O" ring face seal. Lubricate the "O" ring face seal using petroleum jelly, or equivalent. Tighten the fitting to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
14. Connect the HPL and the FTP sensor harness connectors.
15. Begin to fill the fuel tank and with the Combustible Gas Detector (J 45878) check the HPL "O" ring for leaks at each of the following pressures: 500 psi (3447 kPa) 1500 psi (10342 kPa) 3000 psi (20684 kPa)
16. Connect the negative battery cable. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
17. Start the engine and use the Combustible Gas Detector to check for CNG fuel system leaks at each serviced fitting.
18. Install the tank vent boot cover and nuts. Tighten the nuts to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
19. Install the fuel tank cover. Tighten the fuel tank cover nuts to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .

IDLE AIR CONTROL VALVE

IAC valve is located on side of throttle body. (Scheme 48)

1. Turn ignition switch to OFF position.
2. Disconnect negative battery cable.
3. Remove the air cleaner outlet resonator.
4. Disconnect harness connector from IAC valve.
5. Remove IAC valve screw.
6. Remove IAC valve and seal from throttle body assembly.

Scheme 48

LOW PRESSURE LOCK-OFF SOLENOID

1. Low Pressure Lock-Off (LPL) solenoid is mounted in the Intermediate pressure line. (Scheme 54) Release CNG fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE (CNG)»(ref-153402-S10765672692003040400000) under FUEL SYSTEMS (CNG).
2. Remove the battery, air cleaner outlet duct and the air cleaner assembly.
3. Disconnect the fuel line from the LPL fuel inlet elbow. (Scheme 53)
4. Remove the fuel rail feed hose hold-down nut and retainer. (Scheme 49)
5. Remove the fuel feed hose from the LPR using a twisting motion.
6. Disconnect the LPL harness connector.
7. Remove the LPR/LPL mounting bracket nuts. (Scheme 49)
8. Remove the LPR/LPL assembly from the vehicle.
9. Remove the LPR and LPL mounting bolts.
10. Remove the LPR/LPL assembly from the mounting bracket.
11. While holding the union with a wrench, rotate the LPL to separate the components. (Scheme 50)

Scheme 49

Scheme 50

1. While holding the union with a wrench, rotate the LPL as necessary to attach the components. Tighten the LPL 1-3 turns from hand tight as necessary to properly align and seal the LPL and LPR to the union.
2. Loosely install the LPR mounting bolts through the mounting bracket and into the LPR.
3. Loosely install the LPL mounting bolts through the mounting bracket and into the LPR. Tighten the mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
4. Place the LPR/LPL mounting bracket onto the transmission housing studs. (Scheme 51)
5. Install the LPR/LPL mounting nuts onto the mounting studs. Tighten the nuts to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
6. Install the fuel feed hose at the regulator using a NEW "O" ring. Lubricate the "O" ring with petroleum jelly, or equivalent. (Scheme 49)
7. Install the fuel hose retainer and the hold-down nut. Tighten the nut to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
8. Install the fuel line to the LPL fuel inlet elbow using a NEW "O" ring face seal. Lubricate the "O" ring face seal with petroleum jelly, or equivalent. Tighten the fuel line fitting to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
9. Connect the LPL harness connector.
10. Install the battery, air cleaner outlet duct and the air cleaner assembly.
11. Start the engine. Check for CNG fuel leaks at each serviced fitting using the Combustible Gas Detector (J 45878).

Scheme 51

FUEL SYSTEMS (CNG)

Note. Procedures apply only to Cavalier with 2.2L Bi-Fuel - CNG/Gasoline engine.

FUEL SYSTEM PRESSURE RELEASE (CNG)

Note. If High Pressure Lock-Off (HPL) is replaced, or tank is to be cleaned, replaced or shipped, also perform FUEL TANK VENTING .

1. With a scan tool communicate with the PCM. If communication cannot be established and the Diagnostic System Check - Alternative Fuels (Engine Controls) has already been performed proceed to step 9.
2. Store the DTC Information using a scan tool.
3. Clear the DTC Information using a scan tool.
4. Turn ignition switch to OFF position.
5. Start and idle the engine. If the engine fails to operate on CNG or start at all, proceed to step 9.
6. Ensure that the engine is operating on CNG by observing the following: The Fuel Indicator Light (FIL) is OFF. The AFO Enable scan tool display indicates the engine is operating on alternative fuel.
7. Using a scan tool, select the High Pressure Lock-Off (HPL) solenoid special function.
8. While the engine is operating on CNG command the HPL solenoid OFF and observe the fuel tank pressure sensor data parameter. The fuel tank pressure should slowly decrease. If the fuel pressure fails to decrease proceed to next step. When the engine stalls or a switch-over to gasoline is observed, perform the following: Turn ignition switch to OFF position. Remove the ALT. FUELS LOCK-OFF fuse (10-amp) to disable the CNG fuel system. A small amount of CNG will remain in the fuel lines and components. Slowly open the fittings to release any remaining pressure when disconnecting a fuel line. Fuel Pressure Relief for the CNG system is now complete. Proceed to step 16.
9. Close the manual lock-down screw located on the end of the High Pressure Lock-Off (HPL) solenoid. The manual shut-off fitting is closed by rotating the Allen screw clockwise until fully seated. (Scheme 52)
10. Turn ignition switch to OFF position.
11. Disconnect the negative battery cable.
12. Slowly loosen the fuel line fitting at the Low Pressure Lock-Off (LPL) solenoid elbow several turns. (Scheme 53)
13. Fuel Pressure Relief for the CNG system is complete when the fuel line can be pulled away from the "O" ring face seal and fuel does not vent.
14. Replace the "O" ring face seals at all fittings that were disconnected or loosened.
15. After all necessary repairs are complete perform the following: Tighten any loosened fittings to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000). NOTE: Leave the manual lock-down screw closed on any vehicle that will require CNG fuel tank venting. Open the manual lock-down screw located on the HPL manual shut-off fitting by rotating the Allen screw counter-clockwise until fully seated on any vehicle that does not require venting of the CNG fuel tanks.
16. If the service necessary for the vehicle requires the CNG fuel tanks to be relieved of all internal pressure, go to «FUEL TANK VENTING»(ref-153402-S00524229582003040400000).

Scheme 52

Scheme 53

Scheme 54

Note. The fill line union may also be referred to as check valve.

1. Relieve the CNG fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE (CNG)»(ref-153402-S10765672692003040400000).
2. Disconnect the negative battery cable.
3. Remove the fuel tank cover. (Scheme 75)
4. Remove the tank vent boot cover nuts and the cover.
5. Disconnect the three harness connectors.
6. Loosen the clamp at the tank vent boot and peel back the boot to expose the union. (Scheme 58)
7. Disconnect the fill lines at the union.
8. Remove the fill line union.

1. Install the fill line union (check valve) using NEW "O" ring face seals. Lubricate the "O" rings with petroleum jelly, or equivalent. Tighten the fill line union fittings to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
2. Connect the negative battery cable. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
3. Connect the three harness connectors and the HPL harness connector.
4. Start the engine. Check for CNG fuel leaks at each serviced fitting using the Combustible Gas Detector (J 45878).
5. Slip the tank vent boot over the union. Tighten the boot clamp to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
6. Install the tank vent boot cover. Tighten the tank vent boot cover nuts to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
7. Install the fuel tank cover.

Note. If the fill valve is being replaced due to a leaking condition, check the fill line union check valve for proper operation.

Note. The numbers in parenthesis correspond to numbered components in referenced illustrations.

1. Relieve the CNG fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE (CNG)»(ref-153402-S10765672692003040400000).
2. Disconnect the negative battery cable.
3. Remove the trunk trim panel.
4. Remove the cargo net, the cargo net knobs and the left wheelhouse carpet.
5. Loosen the fill valve boot clamp and peel back the boot.
6. Disconnect the fill line (3) at the fill valve (5). (Scheme 55)
7. Remove the fill valve retaining nut (1). (Scheme 55)
8. Remove the fill valve from the fill door assembly. (Scheme 56)
9. If fill valve filter is to be changed, see «FILL VALVE FILTER»(ref-153402-S20456545992003061900000).

Scheme 55

Scheme 56

1. Install the fill valve through the fill door assembly.
2. Loosely install the mounting nut.
3. Tighten the fill valve retaining nut (1) while holding the fill valve using a wrench (4). Tighten the fill valve retaining nut to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
4. Connect the fill line (3) to the fill valve (5) with a new "O" ring face seal. Lubricate the "O" ring with petroleum jelly, or equivalent. Tighten the fill line fitting to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
5. Connect the negative battery cable. Tighten the bolt to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
6. Connect the HPL harness connector.
7. Start the engine. Check for CNG fuel leaks at each serviced fitting using the Combustible Gas Detector (J 45878), or equivalent.
8. Slip the boot over the fill valve fitting. Tighten the fill valve boot clamp to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
9. Install the left carpet and the cargo net.
10. Install the trunk trim panel.
11. Connect the negative battery cable. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .

1. Remove the "O" ring. (Scheme 57)
2. Remove the circlip.
3. Remove the fill valve filter.
4. Clean the filter in solvent.
5. Blow dry the filter using compressed air.
6. Be sure that the filter passages are clear. Replace the filter if necessary.
7. To install, reverse removal procedures.

Scheme 57

Note. The numbers in parenthesis correspond to numbered components in referenced illustrations.

1. Relieve the CNG fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE (CNG)»(ref-153402-S10765672692003040400000).
2. Disconnect the negative battery cable.
3. Remove the fuel tank cover. (Scheme 75)
4. Remove the trunk trim panel.
5. Remove the cargo net, the cargo net knobs and the left wheelhouse carpet.
6. Loosen the fill valve boot clamp and peel back the boot. (Scheme 67)
7. Disconnect the fill line (3) at the fill valve (5). (Scheme 55)
8. Loosen the clamp at the tank vent boot and peel back the boot to expose the union. (Scheme 58)
9. Disconnect the fill line at the union.
10. Remove the fill line from the vehicle.

Scheme 58

1. Install the fill line at the union with a new "O" ring face seal. Lubricate the "O" ring with petroleum jelly or equivalent. Tighten the fill line fitting to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
2. Install the fill line (3) at the fill valve (5) with a new "O" ring face seal. Lubricate the "O" ring with petroleum jelly, or equivalent. Tighten the fill line fitting to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
3. Connect the negative battery cable. Tighten the bolt to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
4. Connect the HPL power harness connector.
5. Start the engine. Check for CNG fuel leaks at each serviced fitting using the Combustible Gas Detector (J 45878), or equivalent.
6. Slip the vent boot over the fill valve fitting. Tighten the fill valve boot clamp to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000) .
7. Install the left wheelhouse carpet, the cargo net knobs and the cargo net.
8. Install the trunk trim panel.
9. Install the fuel tank cover.

FUEL GAUGE SELECT SWITCH

See FUEL GAUGE SELECT SWITCH under SENSORS & SWITCHES.

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE (CNG)»(ref-153402-S10765672692003040400000). Disconnect negative battery cable.
2. Disconnect the engine fuel pipes from the engine fuel flex hoses. Remove the engine fuel supply and return pipes. See «FUEL LINE QUICK CONNECT FITTINGS»(ref-153402-S13027093362003040400000) under FUEL SYSTEMS (GASOLINE).
3. Use a back-up wrench on the fuel pressure regulator and disconnect the return line.
4. Disconnect the fuel feed line from the fuel rail. (Scheme 59)
5. Remove the engine fuel pipes fasteners located on the engine. (Scheme 60)
6. Remove the engine fuel pipes.
7. Remove the air cleaner outlet resonator.
8. Disconnect the vent pipe from the fuel pressure regulator. (Scheme 61)
9. Remove the retaining bolt from the fuel pressure regulator.
10. Remove the fuel pressure regulator. (Scheme 62)
11. Disconnect the fuel injector harness connectors.
12. Remove the fuel rail attaching studs. (Scheme 63)
13. Remove the fuel rail using the following procedure: Pull the fuel rail back and upward to remove the fuel injectors from the cylinder head ports. Rotate the fuel rail to position the injectors downward. Remove the fuel rail.
14. Disconnect the fuel injector harness connector.
15. Remove the fuel injector retainer clip. (Scheme 64)
16. Remove the fuel injectors from the fuel rail. (Scheme 65)
17. Visually inspect the fuel injector to determine if the upper "O" ring was also removed. If the upper "O" ring in not removed, remove the "O" ring from the fuel rail assembly.
18. If the fuel injector insulator cups are removed from the cylinder head while removing the fuel rail, NEW insulator cups must be installed.
19. Remove and discard the fuel injector "O" rings.

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

1. If the fuel injector insulator cups are removed from the cylinder head while removing the fuel rail, NEW insulator cups must be installed. (Scheme 66)
2. Install NEW "O" rings on the fuel injectors.
3. Install the fuel injectors to fuel rail.
4. Install the fuel injector clips.
5. Install the fuel rail using the following procedure: With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports. Align the injectors by rotating the fuel rail forward. Carefully push the fuel injectors into the cylinder head ports.
6. Install the fuel rail attaching studs. Tighten the fuel rail studs to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
7. Connect the fuel injector harness connectors. Pull back to insure the connectors are locked in place.
8. Connect the fuel supply and return pipes.
9. Install the fuel pressure regulator. Install the fuel pressure regulator bolt. Tighten the fuel pressure regulator bolt to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
10. Connect the vent pipe to the fuel pressure regulator.
11. Install the air cleaner outlet resonator.
12. Connect the negative battery cable. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
13. Check for fuel leaks using the following procedure: Turn ignition switch to RUN position, with the engine OFF for 2 seconds. Turn ignition switch to OFF position for 10 seconds. Turn ignition switch to RUN position. Check for fuel leaks.

Scheme 66

FUEL TANK

1. Remove spare tire cover. Remove jack and tool kit. Remove spare tire. Remove 4 tank cover bolts. Remove the CNG tank cover. (Scheme 75)
2. Relieve the system pressure. See «FUEL SYSTEM PRESSURE RELEASE (CNG)»(ref-153402-S10765672692003040400000).
3. Disconnect the negative battery cable.
4. Remove the tank vent boot cover nuts and cover. (Scheme 76)
5. Disconnect the 3 harness connectors.
6. Loosen the fill valve boot clamp and peel back the boot. (Scheme 67)
7. Disconnect the fill line at the fill valve.
8. Loosen the clamp at the tank vent boot and peel back the boot to expose the union.
9. Disconnect the fill line at the union. (Scheme 77)
10. Disconnect the fill line at the HPL.
11. Disconnect the HPL to HPR fuel line at the HPL.
12. Disconnect the Pressure Relief Device (PRD) line at the HPL.
13. Remove the trunk trim panel.
14. Remove the cargo net, the cargo net knobs and the left wheelhouse carpet.
15. Remove the fill line from the fill valve to the union.
16. Lower the rear seat.
17. Loosen the vent hose clamps at the tank valve boot and the HPR mounting ring.
18. Pull up the boot and loosen the fuel line at the HPR.
19. Remove the lines and the vent boot as an assembly.
20. Remove the spare tire bracket. (Scheme 68)
21. Mark the tank in 2 places approximately 180 degrees apart for re-installation reference.
22. Remove the tank strap nuts and the bolts. (Scheme 69) Discard the nuts and the bolts.
23. Remove the clevis and the bridge pins. (Scheme 70)
24. Remove the tank straps.
25. Position the CNG Tank Remover (J 43133), or equivalent, into the tank strap bolt holes. (Scheme 71)
26. Loop the Tank Remover straps around the tank and secure the straps to the tool. (Scheme 72)
27. Pull back the Tank Remover to pull the tank free from the bracket.
28. Pull back on the straps to roll the tank to the upper level of the CNG Tank Remover. (Scheme 73)
29. Use a lifting device and the CNG Tank Sling (J 45529) to remove the tank from the vehicle. (Scheme 74)
30. Remove the Tank Remover with tank from the vehicle.

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

FUEL TANK PRESSURE SENSOR

See FUEL TANK PRESSURE SENSOR (CNG) under SENSORS & SWITCHES.

Note. Fuel Tank Temperature (FTT) sensor is a thermistor mounted inside the High Pressure Lock-Off (HPL) and is not serviceable separately from the HPL. See HIGH PRESSURE LOCK-OFF SOLENOID under RELAYS & SOLENOIDS.

FUEL TANK VENTING

Note. Venting the CNG fuel tank will damage the HPL. Venting is only necessary for High Pressure Lock-Off (HPL) replacement, internal tank cleaning, tank replacement or tank shipping.

Note. Numbers in text correspond to numbered components in referenced figures.

1. Remove spare tire cover. Remove jack and tool kit. Remove spare tire. Remove 4 tank cover bolts. Remove tank cover. (Scheme 75)
2. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE (CNG)»(ref-153402-S10765672692003040400000).
3. Turn ignition switch to OFF position. Disconnect negative battery cable.
4. Remove the fuel line vent boot cover nuts. (Scheme 76) Remove fuel line vent boot cover.
5. Disconnect all harness connectors to remove the vent boot cover from the tank area.
6. Disconnect the CNG fuel fill line from the HPL. (Scheme 77)
7. Remove the Fuel Tank Pressure (FTP) sensor (2). (Scheme 78)
8. Disconnect the CNG fuel outlet line from the HPL fitting (1).
9. Install a cap (9) supplied with CNG tank venting kit onto the fuel outlet line fitting (8). Tighten the caps to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000). (Scheme 79)
10. Install an appropriate fitting from the CNG Tank Venting Kit, on FTP sensor port. Tighten fitting to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000). (Scheme 79)
11. Install a cap supplied from the CNG Tank Venting Kit, to FTP sensor port fitting. Tighten the cap to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000). (Scheme 79)
12. Remove the fill line HPL fitting (3). (Scheme 78)
13. Install the fitting (4) supplied in the CNG Tank Venting Kit that threads into both the HPL fill line port and the CNG vent hose female fitting. Tighten the fitting to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000). (Scheme 79)
14. Connect the female end of the vent hose to the fill line fitting. (Scheme 80)
15. Connect the male end of the vent hose (6) to a vent stack.
16. Connect the ground strap (4) to the FTP port fitting (3) and to the vent stack earth ground (5). (Scheme 80)
17. Ensure that the manual lock-down screw of the manual shut-off fitting (2) is open by rotating the Allen screw counterclockwise until fully seated.
18. If the tank begins venting when the manual lock-down screw is opened, DO NOT proceed to the next step until the tank stops venting.
19. Remove the manual shut-off fitting from the HPL. (Scheme 81)
20. Obtain the manual vent tool supplied from the CNG Tank Venting Kit.
21. Rotate the screw on the manual vent tool counterclockwise to fully retract the plunger.
22. Install the manual vent tool into the HPL port with the plunger fully retracted. Tighten the manual vent tool to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
23. Slowly turn the manual vent tool screw clockwise until the plunger is fully extended. (Scheme 82)
24. Open the CNG Tank Venting Kit in-line valve. The tank should always contain some pressure and begin to vent.
25. Allow the CNG fuel tank to vent until the pressure gauge reads zero psi (zero kPa). If the tank stops venting and pressure is indicated on the CNG Tank Venting Kit gauge, check the vent line for a frozen fitting. The fitting will eventually thaw and fuel will again continue to vent.
26. When the tank is completely vented remove the vent line (6) from the fuel fitting. (Scheme 80)
27. Remove the fitting and cap (3) from the FTP port. (Scheme 80)
28. Remove the fuel fitting cap from the fuel outlet port.
29. Remove the fitting from the fuel fill line port.
30. Remove the manual vent tool (2). (Scheme 80)
31. If the tank is to be re-used replace the high pressure lock-off.

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

See HIGH PRESSURE LOCK-OFF SOLENOID under RELAYS & SOLENOIDS.

HIGH PRESSURE REGULATOR

See LOW PRESSURE LOCK-OFF SOLENOID under RELAYS & SOLENOIDS.

1. Relieve the CNG fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE (CNG)»(ref-153402-S10765672692003040400000).
2. Remove the battery, air cleaner outlet duct and the air cleaner assembly.
3. Disconnect the fuel line from the LPL fuel inlet elbow. (Scheme 53)
4. Remove the retaining bolt from the fuel pressure regulator.
5. Remove the fuel feed hose from the LPR using a twisting motion.
6. Disconnect the LPL harness connector.
7. Remove the LPR/LPL mounting bracket nuts.
8. Remove the LPR/LPL assembly from the vehicle.
9. Remove the LPR and LPL mounting bolts.
10. Remove the LPR/LPL assembly from the mounting bracket.
11. While holding the union with a wrench, rotate the LPL to separate the components. (Scheme 50)

1. While holding the union with a wrench, rotate the LPL as necessary to attach the components. Tighten the LPL 1-3 turns from hand tight as necessary to properly align and seal the LPL and LPR to the union. (Scheme 50)
2. Loosely install the LPR mounting bolts through the mounting bracket and into the LPR.
3. Loosely install the LPL mounting bolts through the mounting bracket and into the LPR. Tighten the mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
4. Place the LPR/LPL mounting bracket onto the transmission housing studs. (Scheme 51)
5. Install the LPR/LPL mounting nuts (3) onto the mounting studs. Tighten the nuts to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
6. Install the fuel feed hose at the regulator using a NEW "O" ring. Lubricate the "O" ring with petroleum jelly, or equivalent.
7. Install the fuel hose retainer and the hold-down nut. Tighten the nut to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
8. Install the fuel line to the LPL fuel inlet elbow using a NEW "O" ring face seal. Lubricate the "O" ring face seal with petroleum jelly, or equivalent. Tighten the fuel line fitting to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
9. Connect the LPL harness connector.
10. Install the battery, air cleaner outlet duct and the air cleaner assembly.
11. Start the engine. Check for CNG fuel leaks at each serviced fitting using the Combustible Gas Detector (J 45878).

FUEL SYSTEM SAFETY PRECAUTIONS

FUEL SYSTEM PRESSURE RELEASE (GASOLINE)

Fuel system is under pressure. Pressure must be released prior to servicing fuel system. Fuel pressure may be released by using the following method

1. Disconnect the negative battery cable.
2. Connect the Fuel Pressure Gauge (J 34730-1A), or equivalent, to the fuel pressure connection. (Scheme 83)
3. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing.
4. Disconnect the fuel pressure gauge from the fuel pressure connection.

Scheme 83

See FUEL LEVEL SENSOR under SENSORS & SWITCHES.

FUEL PRESSURE REGULATOR

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

Fuel pressure regulator is mounted to the fuel rail.

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE (GASOLINE)»(ref-153402-S34229557402003040400000).
2. Disconnect negative battery cable. Disconnect the vacuum pipe from the fuel pressure regulator. (Scheme 61)
3. Place a shop towel under the fuel pressure regulator to catch any fuel spillage.
4. Remove the retaining bolt from the fuel pressure regulator.
5. Remove the fuel pressure regulator. (Scheme 62)
6. Remove any seal or seal material left on the fuel rail.

Note. Lubricate the "O" rings with clean engine oil before installation.

1. Install the fuel pressure regulator to the fuel rail. (Scheme 62)
2. Install the fuel pressure regulator retaining bolt. Tighten the retaining bolt to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
3. Connect the vacuum pipe to the fuel pressure regulator.
4. Connect the negative battery cable.
5. Check for leaks using the following procedure: Turn ignition switch to RUN position for 2 seconds. Turn ignition switch to OFF position for 10 seconds. Turn ignition switch to RUN position. Check for fuel leaks.
6. Place the shop towel into a suitable storage container.

FUEL PUMP

Note. Fuel pump is located in fuel tank and is integral with fuel sender assembly. See FUEL SENDER ASSEMBLY .

FUEL RAIL & INJECTORS

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

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE (GASOLINE)»(ref-153402-S34229557402003040400000).
2. Disconnect the engine fuel pipes from the engine fuel flex hoses. See «FUEL LINE QUICK CONNECT FITTINGS»(ref-153402-S13027093362003040400000).
3. Use a back up wrench on the fuel pressure regulator and disconnect the return line.
4. Disconnect the fuel feed line from the fuel rail.
5. Remove the engine fuel pipes fasteners located on the engine. (Scheme 60)
6. Remove the engine fuel supply and return pipes.
7. Remove the air cleaner outlet resonator.
8. Disconnect the vacuum pipe from the fuel pressure regulator. (Scheme 61)
9. Remove the retaining bolt from the fuel pressure regulator.
10. Remove the fuel pressure regulator. (Scheme 62)
11. Disconnect the fuel injector harness connectors.
12. Remove the fuel rail attaching studs. (Scheme 63)
13. Remove the fuel rail using the following procedure: Pull the fuel rail back and upward to remove the fuel injectors from the cylinder head ports. Rotate the fuel rail to position the injectors downward. Remove the fuel rail.
14. Remove the fuel injector retainer clip. (Scheme 64)
15. Remove the fuel injectors from the fuel rail. (Scheme 65)
16. Remove and discard the fuel injector "O" rings.

1. If the fuel injector insulator cups are removed from the cylinder head while removing the fuel rail, NEW insulator cups must be installed. (Scheme 66)
2. Install the "O" rings on the fuel injector.
3. Install the fuel injectors to the fuel rail.
4. Install the fuel injector clip. (Scheme 64)
5. Install the fuel injector harness connector.
6. Install the fuel rail using the following procedure: With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports. Align the injectors by rotating the fuel rail forward. Carefully push the fuel injectors into the cylinder head ports.
7. Install the fuel rail attaching studs. (Scheme 63) Tighten the fuel rail studs to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
8. Connect the fuel injector harness connectors. Pull back on connector to insure the connectors are locked in place.
9. Install the fuel supply and return pipes.
10. Install the fuel pressure regulator. (Scheme 62)
11. Install the fuel pressure regulator bolt. Tighten the fuel pressure regulator bolt to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
12. Connect the vent pipe to the fuel pressure regulator. (Scheme 61)
13. Install the air cleaner outlet resonator.
14. Connect the negative battery cable. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
15. Check for fuel leaks using the following procedure: Turn ignition switch to RUN position for 2 seconds. Turn ignition switch to OFF position for 10 seconds. Turn ignition switch to RUN position. Check for fuel leaks.

Fuel System Cleaning

Note. If the fuel filter is plugged, the fuel tank should be inspected internally and cleaned if necessary.

1. Remove the fuel tank, if not already removed. See «FUEL TANK»(ref-153402-S19914623502003040400000) .
2. Remove the fuel sender assembly from fuel tank, if not already removed. See «FUEL LEVEL SENSOR»(ref-153402-S07791538982003090300000) .
3. Check the fuel sender strainer. Replace the fuel sender assembly if the fuel strainer is contaminated.
4. Check the fuel pump inlet for dirt and debris. If dirt and debris are found, the fuel pump needs to be replaced.
5. Flush the fuel tank using hot water.
6. Pour the water out of the fuel sender assembly opening in the fuel tank. Rock the fuel tank to be sure that the removal of the water from the fuel tank is complete.
7. Allow tank to dry completely before reassembly.
8. Disconnect the fuel pipes at the engine compartment. See «FUEL LINE QUICK CONNECT FITTINGS»(ref-153402-S13027093362003040400000) .
9. Clean the fuel pipes by applying air pressure in the opposite direction of the fuel flow.
10. Connect the fuel pipes at the engine compartment.
11. Replace the fuel filter.
12. Install the fuel sender assembly.
13. Install the fuel tank. See «INSTALLATION»(ref-153402-S26280253402003040400000) .

1. With the aid of an assistant, raise the fuel tank to the vehicle. see scheme 78
2. Install the fuel tank retaining straps. Tighten the strap bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
3. Connect the EVAP vapor pipe to the EVAP canister.
4. Connect the wiring harness into the multi-way rear body connector.
5. Connect the fuel filler hose to the fuel tank. Tighten the fuel filler hose clamp to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
6. Install the rubber exhaust hangers.
7. Install the exhaust heat shield. Tighten the exhaust shield nuts/bolt to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
8. Connect the fuel return pipe and fuel filter quick-connect fittings. See «FUEL LINE QUICK CONNECT FITTINGS»(ref-153402-S13027093362003040400000).
9. Lower the vehicle.
10. Refill the fuel tank.
11. Install the fuel filler cap.
12. Connect the negative battery cable. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
13. Check for leaks by using the following procedure: Turn ignition switch to RUN position for 2 seconds. Turn ignition switch to OFF position for 10 seconds. Turn ignition switch to RUN position. Check for fuel leaks.

See FUEL TANK PRESSURE SENSOR under SENSORS & SWITCHES.

See INTAKE AIR TEMPERATURE SENSOR under SENSORS & SWITCHES.

MANIFOLD ABSOLUTE PRESSURE SENSOR

See MANIFOLD ABSOLUTE PRESSURE SENSOR under SENSORS & SWITCHES.

THROTTLE POSITION SENSOR

See THROTTLE POSITION SENSOR under SENSORS & SWITCHES.

CRANKSHAFT POSITION SENSOR

See CRANKSHAFT POSITION SENSOR under SENSORS & SWITCHES.

IGNITION COIL HOUSING

The ignition coils are located in a housing in the camshaft cover. (Scheme 84)

1. Turn ignition switch to OFF position. Disconnect negative battery cable.
2. Remove the accelerator and cruise control cables from the bracket, if equipped.
3. Remove the bracket.
4. Disconnect the Ignition Control Module (ICM) harness connector.
5. Remove the ICM retaining screws.
6. Remove the ICM from the ignition coil housing. (Scheme 85)
7. Remove the ignition coil housing retaining bolts.
8. Remove the ignition coil housing from the camshaft cover.

Scheme 84

Scheme 85

1. Ensure the interconnect and seal are lined up before module installation. Install the Ignition Control Module (ICM) in the ignition coil housing. (Scheme 85)
2. Install the ICM retaining bolts. Tighten retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
3. Connect the ICM harness connector.
4. Install the ignition coil housing to the camshaft cover.
5. Install the ignition coil housing retaining bolts. Tighten the retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
6. Install the accelerator and cruise control cables bracket.
7. Install the accelerator and cruise control cables bracket bolts. Tighten the retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).
8. Install the accelerator and cruise control cables to the bracket.
9. Connect the negative battery cable. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153402-S15109679952003040400000).

IGNITION CONTROL MODULE

Note. For Ignition Control Module removal & installation procedure, see IGNITION COIL HOUSING .

KNOCK SENSOR

See KNOCK SENSOR under SENSORS & SWITCHES.

SPARK PLUGS

1. Remove the ignition coil housing. See «IGNITION COIL HOUSING»(ref-153402-S39801531862003040400000) .
2. Remove any water and debris from the spark plug holes before spark plug removal with compressed air.
3. Remove the spark plugs using appropriate spark plug socket.
4. Check the spark plugs.

EVAP CANISTER PURGE VALVE

See EVAP CANISTER PURGE VALVE under RELAYS & SOLENOIDS.

EVAP CANISTER VENT VALVE

See EVAP CANISTER VENT VALVE under RELAYS & SOLENOIDS.

EVAP SYSTEM CLEANING

Cleaning Procedure

1. Raise and support the vehicle.
2. Remove the EVAP canister. See «EVAP CANISTER»(ref-153402-S19897953652003040400000) .
3. Turn OFF the main valve on the EVAP Pressure and Purge Station.
4. Disconnect the hose from the diagnostic station pressure regulator.
5. Using a section of vacuum hose, connect one end onto the EVAP pressure/purge diagnostic station pressure regulator.
6. Connect the other end of the vacuum hose to the canister side of the purge pipe.
7. Turn ON the main nitrogen cylinder valve and continue to discharge nitrogen for 15 seconds.
8. If the nitrogen does not clear the blockage, replace the purge pipe.
9. Return the EVAP pressure/purge diagnostic station to the stations original condition.
10. Install a NEW EVAP canister. See «EVAP CANISTER»(ref-153402-S19897953652003040400000) .
11. Lower the vehicle.
12. Install a new EVAP canister purge valve. See «EVAP CANISTER PURGE VALVE»(ref-153402-S11804849062003090300000) under RELAYS & SOLENOIDS.
13. Return to the diagnostic table that sent you here.