Engine Control System - Removal & Installation: Other Pontiac Vibe I

SERVICE PRECAUTIONS

Note. Before performing removal and installation procedures, check for any related Technical Service Bulletins (TSBs).

IGNITION SWITCH & PCM CONNECTORS

Turn ignition switch to OFF position when installing or removing the PCM connectors and disconnecting or reconnecting the power to the PCM (battery cable, PCM pigtail, PCM fuse, jumper cables, etc.) to prevent internal PCM damage.

SUPPLEMENTAL INFLATABLE RESTRAINT SYSTEM

When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. See DISABLING & ACTIVATING AIR BAG SYSTEM in appropriate AIR BAG RESTRAINT SYSTEM article in RESTRAINTS. Failure to observe the correct procedure could cause deployment of the SIR components, personal injury, or unnecessary SIR system repairs.

COMPUTERIZED ENGINE CONTROLS

POWERTRAIN CONTROL MODULE

Note. Service of the Powertrain Control Module (PCM) consists of a complete replacement of the PCM. There are no serviceable parts, such as Programmable Read-Only Memory (PROM) or Erasable Programmable Read-Only Memory (EPROM) to replace inside the PCM. If the PCM is determined to be faulty, the PCM is to be replaced as a complete assembly.

Note. Numbers in parenthesis in removal and installation procedures refer to numbers in referenced figure(s).

1. Disable the Supplemental Inflatable Restraint (SIR) system. See DISABLING & ACTIVATING AIR BAG SYSTEM in appropriate AIR BAG RESTRAINT SYSTEM article in RESTRAINTS.
2. Remove the 2 screws from the PCM close out panel (1) below the Instrument Panel (IP) compartment door. (Scheme 7)
3. Swing the PCM close out panel (1) down.
4. Open IP compartment.
5. Push in on both sides of the IP compartment to release the safety catches. (Scheme 8)
6. Remove the IP compartment door assembly from the IP.
7. Remove the 2 PCM bracket bolts. (Scheme 9)
8. Pull the PCM (2) with brackets (3) forward and swing both down and away from under the IP. (Scheme 10)
9. Disconnect 4 PCM harness connectors (1).
10. Remove the 4 screws and the 2 brackets (3) from the PCM (2).

Scheme 7

Scheme 8

Scheme 9

Scheme 10

1. Install the 2 PCM brackets (3) to the PCM (2). (Scheme 10)
2. Install 4 bracket-to-PCM bolts. Tighten PCM bracket bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
3. Connect PCM harness connectors (1).
4. Swing the PCM (2) with bracket (3) up into position under the IP. (Scheme 10)
5. Install 2 PCM-to-IP bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). (Scheme 9)
6. Install the IP compartment door into the IP.
7. Push in on both sides of the IP compartment to release the safety catches and close the door. (Scheme 8)
8. Swing the close out panel (1) up under the PCM and install the 2 retainers. (Scheme 7)
9. Enable the SIR system. See DISABLING & ACTIVATING AIR BAG SYSTEM in appropriate AIR BAG RESTRAINT SYSTEM article in RESTRAINTS.

Note. The following information/procedure is as per Service Bulletin No. 02-09-04-001-(05/24/2002): DTCs B1001, B1271 or B1780 SET WHEN REPLACING/REPROGRAMMING OTHER MODULES.

Class 2 Serial Data Communication allows control modules to exchange information. This information may be operational information or identification information. Among the identification information exchanged and compared within these modules is the Vehicle Identification Number (VIN). Typically the one module, the master module, broadcasts the VIN and all the other modules compare the VIN stored within itself. When the broadcast VIN does not match the VIN stored within the Sensing and Diagnostic Control Module (SDM), the following actions occur

1. DTC B1001 Option Configuration Error is set and deployment of the air bags is inhibited.
2. DTC B1271 or a DTC B1780 Theft Locked. The VIN information is also used by the radio. When the VIN does not match the VIN stored within the radio, DTC B1271 or DTC B1780 is set and the radio is inoperative.

Additionally, the master module will compare the SDM's part number (last 4 digits) to determine if the correct SDM is installed in the vehicle. If the SDM is the wrong part, DTC B1001 will also set.

When a PCM or a body control type module is replaced, the VIN information must be programmed into the replaced (NEW) control module. A module which has had VIN information entered into it (for example, one taken from another vehicle) cannot be reprogrammed. VIN information can only be entered into new modules. The ignition switch must be in the RUN position to program the NEW control module. Since the VIN information is broadcast when the ignition goes to RUN position from any other ignition switch position, DTCs may be set in the SDM and/or the radio. Therefore, always follow the specified control module replacement procedures

1. After completing the repair, turn ignition switch to OFF position for at least 30 seconds.
2. Turn ignition switch to RUN position and check for DTCs using a Tech 2(R) scan tool, or equivalent. If DTCs B1001, B1271, or B1780 are present with a history status, DO NOT replace the SDM or the radio.
3. Clear DTCs from all modules using the scan tool.
4. Remove scan tool.
5. Ensure proper operation of the SDM by turning the ignition switch to OFF position and then to RUN position. The air bag warning indicator should flash 7 times and then go OFF.

Clearing codes from the other modules is part of the replacement and reprogramming procedure for the replaced module. The repair is not complete unless all codes have been cleared from all modules.

SENSORS & SWITCHES

A/C evaporator temperature sensor is located in evaporator case, next to evaporator core. For servicing of A/C evaporator temperature sensor, see appropriate article in AIR CONDITIONING & HEATING.

BRAKELIGHT SWITCH

Note. Brakelight switch may also be referred to as stoplight switch.

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Disconnect negative battery cable.
2. Disconnect brakelight switch harness connector.
3. Remove the lock nut (2) and brakelight switch (1) from the brake pedal bracket (3). (Scheme 11)

Scheme 11

1. Install the brakelight switch (1) to the brake pedal bracket (3). Secure the brakelight switch (1) using one lock nut (2). (Scheme 11) Do not tighten at this time.
2. Adjust the brakelight switch clearance. Connect brakelight switch harness connector. Connect the negative battery cable. Tighten clamp bolt to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). Turn brakelight switch (2) until the switch lightly contacts the pedal stopper. (Scheme 12) Verify the distance between the end of the brakelight switch plunger and the end of the threaded portion of the brakelight switch is 0.02-0.094" (0.5-2.4 mm). (Scheme 12)
3. Tighten brakelight switch (1) lock nut (2) to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). (Scheme 11)

Scheme 12

CAMSHAFT POSITION SENSOR

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Remove engine cover (1) bolts. see scheme 1
2. Remove engine cover (1). see scheme 1
3. Disconnect CMP sensor harness connector (1). (Scheme 13)
4. Remove CMP sensor hold-down bolts.
5. Remove CMP sensor (2). (Scheme 13)

Scheme 13

1. Install CMP sensor (2) into the cylinder head. (Scheme 13)
2. Install the 2 CMP sensor hold-down bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). (Scheme 13)
3. Connect CMP sensor harness connector (1).
4. Install engine cover (1). see scheme 1
5. Install engine cover (1) bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). see scheme 1

CRANKSHAFT POSITION SENSOR

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Raise and support vehicle.
2. Remove the 2 bolts (3) that secure the stone shield (1). (Scheme 14)
3. Remove the 4 retainers (2) and the stone shield (1).
4. Disconnect CKP sensor harness connector. (Scheme 15)
5. Remove CKP sensor hold-down bolt (2). (Scheme 15)
6. Remove CKP sensor (1) from the front cover of the engine block.

Scheme 14

Scheme 15

1. Install CKP sensor (1) into the front cover of the engine block.
2. Install CKP sensor hold-down bolt (2). Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). (Scheme 15)
3. Connect CKP sensor harness connector.
4. Install stone shield (1) and the 4 retainers (2). (Scheme 14)
5. Install stone shield (1) 2 bolts (3). Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). (Scheme 14)
6. Lower vehicle.

Note. Use care when handling the Engine Coolant Temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system.

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Drain the engine coolant into appropriate container.
2. Disconnect ECT sensor (2) harness connector (1), located next to the upper radiator hose on the cylinder head. (Scheme 16)
3. Remove ECT sensor (2).

Scheme 16

1. Install ECT sensor (2) into cylinder head. Tighten ECT sensor to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000) .
2. Connect ECT sensor harness connector (1).
3. Refill the engine coolant.

HEATED OXYGEN SENSOR 1

Note. The HO2S may be difficult to remove at temperatures exceeding 120°F (48°C). Allow the engine to cool down before attempting to remove the HO2S. Use care in order to prevent any damage to the threads in the exhaust pipe.

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Remove the carpet retaining pin (1) from the front floor console (3). (Scheme 17)
2. Pull back the carpet (2) from the area near the front floor console (3).
3. Disconnect HO2S 1 harness connector (1). (Scheme 18)
4. Raise and support vehicle.
5. Remove HO2S 1 wiring pigtail and body plug (1) from the floor pan.
6. Remove HO2S 1 (2) from the exhaust pipe.

Scheme 17

Scheme 18

1. Apply a coating of anti-seize on the HO2S 1 sensor threads if reusing HO2S. NEW HO2S comes with anti-seize on threads. Install the HO2S 1 (2) into the exhaust pipe.
2. Tighten HO2S 1 to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). (Scheme 18)
3. Install HO2S 1 wiring pigtail and body plug (1) into the floor pan.
4. Lower vehicle.
5. Connect the HO2S 1 harness connector.
6. Install the carpet (2) around the front floor console (3). (Scheme 17)
7. Secure the carpet to the front floor console using the retaining pin (1). (Scheme 17)

HEATED OXYGEN SENSOR 2

Note. The HO2S may be difficult to remove at temperatures exceeding 120°F (48°C). Allow the engine to cool down before attempting to remove the HO2S. Use care in order to prevent any damage to the threads in the exhaust pipe.

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Remove the rear floor console to gain access to the HO2S 2 harness connector.
2. Disconnect the HO2S 2 harness connector (1). (Scheme 19)
3. Raise and support vehicle.
4. Remove HO2S 2 wiring pigtail and body plug (1) from floor pan. (Scheme 20)
5. Remove HO2S 2 (2) from the exhaust pipe.

Scheme 19

Scheme 20

1. Apply a coating of anti-seize on the HO2S 2 sensor threads if reusing HO2S. NEW HO2S comes with anti-seize on threads. Install HO2S 2 (2) into the exhaust pipe. (Scheme 20)
2. Tighten HO2S 2 to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
3. Install the HO2S 2 wiring pigtail and body plug (1) into the floor pan. (Scheme 20)
4. Lower vehicle.
5. Connect HO2S 2 harness connector (1). (Scheme 20)
6. Install the rear floor console.

IGNITION SWITCH

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

Note. For more information on removing and installing the ignition switch, see appropriate STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT.

1. Disable the SIR system. See DISABLING & ACTIVATING AIR BAG SYSTEM in appropriate AIR BAG RESTRAINT SYSTEM article.
2. Remove trim covers from the steering column.
3. Disconnect the ignition switch harness connector (1). (Scheme 21)
4. Remove the 2 screws (8)(9) and the ignition switch (7). (Scheme 21)

Scheme 21

1. Install the ignition switch (7) and the 2 screws (8)(9). (Scheme 21)
2. Connect ignition switch harness connector (1). (Scheme 21)
3. Install trim covers to the steering column.
4. Enable the SIR system. See DISABLING & ACTIVATING AIR BAG SYSTEM in appropriate AIR BAG RESTRAINT SYSTEM article.

INTAKE AIR TEMPERATURE SENSOR

Note. The Intake Air Temperature (IAT) sensor is an integral part of the Mass Air Flow (MAF) sensor and cannot be serviced separately. Replacement of the MAF sensor is required in order to replace the IAT sensor. See MASS AIR FLOW SENSOR .

KNOCK SENSOR

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Remove the intake manifold (1). See appropriate article in ENGINES. (Scheme 22)
2. Disconnect the Knock Sensor (KS) harness connector (2). (Scheme 23)
3. Remove the nut (1) securing KS (2) to the engine block. (Scheme 23)
4. Remove the KS (2) from engine block.

Scheme 22

Scheme 23

1. Install the KS (2) onto the threaded stud in the engine block.
2. Install the KS nut (1) to the threaded stud. (Scheme 23)
3. Align the KS (1) on the engine block as shown in illustration. (Scheme 24) The KS harness connector cavity must point down, in a 15-30 degree arc from perpendicular to the earth, to prevent water accumulation in the KS harness connector cavity.
4. Tighten KS nut while maintaining the correct sensor alignment. Tighten nut to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
5. Connect the KS harness connector.
6. Install the intake manifold. See appropriate article in ENGINES.

Scheme 24

MASS AIR FLOW SENSOR

Note. The Intake Air Temperature (IAT) sensor is an integral part of the Mass Air Flow (MAF) sensor and cannot be serviced separately. Replacement of the MAF sensor includes replacement of the IAT sensor.

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Disconnect Mass Air Flow (MAF) sensor (4) harness connector (1). (Scheme 25)
2. Remove the 2 screws.
3. Remove MAF sensor (4) from the air cleaner housing (2). (Scheme 25)
4. Remove "O" ring (3). (Scheme 25)

Scheme 25

1. Install a NEW "O" ring (3) on MAF sensor. (Scheme 25)
2. Install MAF sensor (4) into the air cleaner housing (2). (Scheme 25)
3. Secure MAF sensor to the air cleaner housing using the 2 screws. Tighten screws to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). (Scheme 25)
4. Connect MAF sensor harness connector (1).

PARK/NEUTRAL POSITION SWITCH

Note. Park/Neutral Position (PNP) is used only on A/T models.

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. The Park/Neutral Position (PNP) switch is located on side of transaxle. Remove the battery.
2. Remove 4 battery tray retaining bolts. Remove the battery tray from the vehicle.
3. Remove the shift cable retaining clip. (Scheme 26)
4. Disconnect the cable from the bracket.
5. Remove the shift cable retaining nut, then disconnect the cable from the manual lever. (Scheme 26)
6. Disconnect the PNP switch harness connector (1). (Scheme 27)
7. Remove nut and lock washer and the manual lever from the manual shaft. (Scheme 28)
8. Unstake the lock plate (1) behind the manual shaft nut (3). (Scheme 28)
9. Remove the manual shaft nut and the lock plate from the PNP switch.
10. Remove 2 PNP switch mounting bolts (2) and the PNP switch from the transaxle.

Scheme 26

Scheme 27

Scheme 28

1. Install the PNP switch to the transaxle. Install 2 mounting bolts (2). Do NOT tighten bolts fully at this time. (Scheme 28)
2. Install a NEW lock plate (1) and the manual shaft nut (3) onto the PNP switch. Tighten the manual shaft nut to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). (Scheme 28)
3. Temporarily install the manual lever.
4. Turn the lever counterclockwise until it stops, then turn it clockwise 2 notches. (Scheme 29)
5. Remove the manual lever.
6. Align the groove (1) with the neutral base line (2). (Scheme 30)
7. Hold switch in position, then tighten mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). (Scheme 28)
8. Stake the lock plate over the manual shaft nut. (Scheme 31)
9. Install the manual lever onto the manual shaft. Secure manual lever using one lock washer and nut. Tighten the manual lever nut to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
10. Install the PNP shift harness connector to the PNP switch. (Scheme 27)
11. Install the shift select cable and nut to the manual lever. Tighten shift cable retaining nut to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
12. Install the shift select cable in the retaining bracket (2) and install the clip (3). (Scheme 32)
13. Install the battery tray and battery tray retaining bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
14. Install the battery.
15. Apply the parking brake and block the vehicle wheels.
16. With the manual selector in Park position, turn the ignition switch to START position and verify that the starter motor operates.
17. Stop the engine and return the ignition switch to RUN position.
18. Move manual selector from Park position to Neutral position and verify that the starter motor operates.
19. Verify that the starter motor DOES NOT operate in D, 2, L or R.

Scheme 29

Scheme 30

Scheme 31

Scheme 32

POWER STEERING PRESSURE SWITCH

Note. Power steering pressure switch may also be referred to as power steering oil pressure switch.

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Raise and support vehicle.
2. Remove right front tire and wheel assembly.
3. Remove right front engine splash shield.
4. Disconnect Power Steering Pressure (PSP) switch harness connector (3). (Scheme 33)
5. Remove PSP switch from the pump.

Scheme 33

1. Apply fluid to the sealing portion of the PSP switch.
2. Install the PSP switch to the pump. Tighten PSP switch to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
3. Verify PSP switch connectors are clean. Connect PSP switch harness connector (3). (Scheme 33)
4. Install right front tire and wheel assembly.
5. Install right front engine splash shield.
6. Lower vehicle.

ROCKER ARM OIL PRESSURE SWITCH

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Remove engine cover (1) bolts. see scheme 1
2. Remove engine cover (1). see scheme 1
3. Disconnect PCV hose (1) from PCV valve. (Scheme 34)
4. Disconnect PCV breather hose (2). (Scheme 34)
5. Disconnect EVAP hose (3). (Scheme 34)
6. Swing the 2 PCV hoses and the EVAP hose away from the cylinder head.
7. Disconnect rocker arm oil pressure switch harness connector.
8. Remove rocker arm oil pressure switch (2) from the rocker arm oil control solenoid housing (1). (Scheme 35)

Scheme 34

Scheme 35

1. Install rocker arm oil pressure switch (2) into the rocker arm oil control solenoid housing (1). Tighten switch to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). (Scheme 35)
2. Connect rocker arm oil pressure switch harness connector.
3. Connect PCV hose (1) and PCV breather hose (2) to the engine. (Scheme 34)
4. Connect EVAP hoses.
5. Install engine cover (1). see scheme 1
6. Install engine cover (1) bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). see scheme 1

THROTTLE POSITION SENSOR

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Remove the inlet air duct from between the air cleaner and throttle body.
2. Remove Throttle Position (TP) sensor (2) mounting screws (3). (Scheme 36)
3. Remove the TP sensor (2) from the throttle body.

Scheme 36

Scheme 37

1. To install, align the throttle shaft (3) with the slot in the TP sensor (2). (Scheme 37)
2. Install the TP sensor (2) to the throttle body (1). (Scheme 37)
3. Install the TP sensor mounting 2 screws (3). Tighten screws to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
4. Install the inlet air duct to the air cleaner and the throttle body.

VEHICLE SPEED SENSOR

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Turn ignition key to OFF position. Disconnect the negative battery cable.
2. Disconnect the Vehicle Speed Sensor (VSS) harness connector (1). (Scheme 38)or (Scheme 39).
3. Remove VSS retaining bolt and the VSS from the transaxle.
4. Inspect the VSS "O" ring for cuts or damage. Replace as necessary.

Scheme 38

Scheme 39

1. Apply Transjel(R) Transmission Assembly Lubricant (J 36850), or equivalent, to VSS "O" ring.
2. Install the VSS into the transaxle case. Install VSS retaining bolt. Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
3. Connect the VSS harness connector (1). (Scheme 38)or (Scheme 39).
4. Connect the negative battery cable.

AUXILIARY INTAKE AIR CONTROL SOLENOID

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Disconnect auxiliary intake air control solenoid harness connector.
2. Disconnect the 2 vacuum lines (2)(3) to the auxiliary intake air control solenoid (4). (Scheme 40)
3. Remove the auxiliary intake air control solenoid mounting bolts (5) and the auxiliary intake air control solenoid (4) from the air cleaner housing. (Scheme 40)

Scheme 40

1. Install the auxiliary intake air control solenoid (4) to the air cleaner housing with the 2 bolts (5). (Scheme 40) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
2. Connect vacuum hoses (2)( 3) to the auxiliary intake air control solenoid (4). (Scheme 40)
3. Connect the auxiliary intake air control solenoid harness connector.

CAMSHAFT POSITION ACTUATOR SOLENOID VALVE

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Remove engine cover (1) bolts. see scheme 1
2. Remove engine cover (1). see scheme 1
3. Remove generator support brace and bolts from intake manifold.
4. Remove bolt (5) that secures lower portion of breather pipe (3) of Positive Crankcase Ventilation (PCV) system. (Scheme 41)
5. Remove 2 nuts (1) securing PCV breather pipe to cylinder head. (Scheme 41)
6. Disconnect PCV breather hose (4) from PCV breather pipe (3). (Scheme 41)
7. Remove PCV breather pipe.
8. Disconnect Camshaft Position (CMP) actuator solenoid valve (2) harness connector (1). (Scheme 42)
9. Remove CMP actuator solenoid valve (1) mounting bolt. (Scheme 43)
10. Remove CMP actuator solenoid valve (1) and "O" ring (2) from cylinder head.

Scheme 41

Scheme 42

Scheme 43

1. Install a NEW "O" ring (2) and CMP actuator solenoid valve (1) to the cylinder head. (Scheme 43)
2. Install CMP actuator solenoid valve mounting bolt. Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
3. Connect CMP actuator solenoid valve (2) harness connector (1). (Scheme 42)
4. Connect PCV breather hose (4) to PCV breather pipe (3).
5. Install PCV breather pipe (3), with a NEW gasket (2), to the cylinder head. (Scheme 41)
6. Secure PCV breather pipe to the cylinder head with the 2 nuts (1). Tighten nuts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). (Scheme 41)
7. Secure lower portion of PCV breather pipe (3) to intake manifold using bolt (5). Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). (Scheme 41)
8. Install generator support brace to intake manifold and secure with 2 bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
9. Install engine cover (1). see scheme 1
10. Install engine cover (1) bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). see scheme 1

EVAP CANISTER PURGE VALVE

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Disconnect EVAP canister purge valve (2) harness connector (1). (Scheme 44)
2. Remove EVAP canister purge valve (2) purge hose (3).
3. Remove EVAP canister purge valve (2) vacuum hose (4).
4. Remove EVAP canister purge valve from the air cleaner housing.
5. Inspect EVAP canister purge valve and EVAP purge system for carbon particle contamination before replacing EVAP canister purge valve.

Scheme 44

1. Install EVAP canister purge valve (2) to air cleaner housing.
2. Connect purge hose (3) to EVAP canister purge valve (2). (Scheme 44)
3. Connect vacuum hose (4) to EVAP canister purge valve (2).
4. Connect EVAP canister purge valve (2) harness connector (1).

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Remove vent hose (4) from the air cleaner and EVAP canister vent valve (3). (Scheme 45)
2. Disconnect the other vent hose (4) from EVAP canister vent valve (3).
3. Disconnect EVAP canister vent valve (3) harness connector (1). (Scheme 45)
4. Remove the bolt (2) from the EVAP canister vent valve (3).
5. Remove the EVAP canister vent valve (1) from the air cleaner housing.
6. Inspect the EVAP canister vent valve and the EVAP vent system for carbon particle contamination before replacing the EVAP canister vent valve.

Scheme 45

1. Inspect EVAP canister vent solenoid valve and the EVAP control system for carbon particle contamination before replacing the EVAP canister vent solenoid.
2. Install EVAP canister vent valve (3) and bolt (2) to air cleaner housing. (Scheme 45)
3. Tighten EVAP canister vent valve bolt (2) to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
4. Connect vent hose (4) to EVAP canister vent valve (3) and air cleaner housing.
5. Connect the other vent hose (4) to EVAP canister vent valve (3).
6. Connect vent valve harness connector (1).

EVAP PRESSURE SWITCHING SOLENOID

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Remove EVAP canister (3). See «EVAP CANISTER»(ref-153233-S04643121612003032600000).
2. Disconnect EVAP pressure switching solenoid harness connector.
3. Disconnect 2 vapor hoses. (Scheme 46)
4. Remove bolt (2).
5. Remove EVAP pressure switching solenoid (1) from EVAP canister.
6. Inspect EVAP pressure switching solenoid and EVAP control system for carbon particle contamination before replacing the EVAP pressure switching solenoid.

Scheme 46

1. Inspect the EVAP pressure switching solenoid and the EVAP control system for carbon particle contamination before replacing the EVAP pressure switching solenoid.
2. Install EVAP pressure switching solenoid (1) to EVAP canister (3).
3. Install bolt (2).
4. Connect the 2 vapor hoses.
5. Connect pressure switching solenoid (1) harness connector.
6. Install EVAP canister (3).

IDLE AIR CONTROL VALVE

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Disconnect Idle Air Control (IAC) valve (1) harness connector (2). (Scheme 47)
2. Drain the cooling system into approved container.
3. Disconnect 2 coolant hoses (2) to IAC valve. (Scheme 48)
4. Remove 3 IAC valve (3) retaining bolts. (Scheme 48)
5. Remove IAC valve (4) from throttle body (1).
6. Remove any remaining IAC valve gasket (4).

Scheme 47

Scheme 48

1. Install a NEW IAC valve gasket (4).
2. Install IAC valve (3) to throttle body. (Scheme 48)
3. Install IAC valve mounting bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
4. Connect coolant hoses (2) to IAC valve. (Scheme 48)
5. Connect IAC valve (1) harness connector (2). (Scheme 48)
6. Refill the cooling system.

ROCKER ARM OIL CONTROL SOLENOID VALVE

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Remove engine cover (1) bolts. see scheme 1
2. Remove engine cover (1). see scheme 1
3. Disconnect PCV hose (1) from PCV valve. (Scheme 34)
4. Disconnect PCV breather hose (2). (Scheme 34)
5. Disconnect EVAP hose (3). (Scheme 34)
6. Swing the 2 PCV hoses and EVAP hose away from the cylinder head.
7. Disconnect rocker arm oil control solenoid valve harness connector.
8. Remove rocker arm oil control solenoid valve retaining bolt.
9. Remove rocker arm oil control solenoid valve (1) and "O" ring (2). (Scheme 49)

Scheme 49

1. Install a NEW "O" ring (2) and rocker arm oil control solenoid valve (1) into the cylinder head. (Scheme 49)
2. Install rocker arm oil control solenoid valve retaining bolt. Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
3. Connect rocker arm oil control solenoid valve solenoid valve harness connector.
4. Connect PCV hose (1) and PCV breather hose (2) to the engine.
5. Connect EVAP hoses.
6. Install engine cover (1). see scheme 1
7. Install engine cover (1) bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). see scheme 1

FUEL SYSTEMS

FUEL SYSTEM PRESSURE RELEASE

Note. Circuit opening relay may also be called the fuel pump relay.

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

1. Loosen fuel filler cap to relieve the fuel tank pressure.
2. Remove the Instrument Panel (IP) storage compartment.
3. Reach in through the IP storage compartment opening and remove the circuit opening relay from the fuse block IP. (Scheme 50)
4. Start the engine and allow the engine to stall.
5. Crank the engine for an additional 3 seconds after stalling to assure relief of any remaining fuel pressure.
6. Disconnect and isolate the negative battery cable to avoid re-pressurizing fuel system. Make necessary checks or repairs. Cover the fuel system components with a shop towel before disconnecting.
7. To activate fuel system, reverse disable procedure. Check fuel system for leaks.
8. Install the IP storage compartment.
9. Install and tighten the fuel filler cap.

Scheme 50

FILL LIMITER VENT VALVE

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Remove fuel tank. See «FUEL TANK»(ref-153233-S28435937452003032700000).
2. Use a screwdriver to release the lock tab of the Fill Limiter Vent Valve (FLVV) cover (1). (Scheme 51)
3. Remove the FLVV cover (1) by rotating the cover counter clockwise while lifting up.
4. Insert a pry tool (2) between the FLVV (1) and the FLVV gasket. (Scheme 52)
5. Lift all around the outer edge of the FLVV and remove the FLVV (1) from the fuel tank.

Scheme 51

Scheme 52

1. Install the FLVV gasket (1) onto the fuel tank. (Scheme 53)
2. Apply a light coat of motor oil to the sealing edge of the FLVV. (Scheme 54)
3. Install the FLVV into the fuel tank while keeping the correct alignment for the hose connections.
4. Place the FLVV cover onto the FLVV and rotate the cover clockwise until the lock tab is in position and engaged.
5. Install fuel tank. See «FUEL TANK»(ref-153233-S28435937452003032700000).

Scheme 53

Scheme 54

The fuel filter is located on fuel pump assembly. See FUEL PUMP for removal and installation procedures.

FUEL PRESSURE GAUGE

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Release the fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-153233-S42569625982003040800000).
2. Remove engine cover (1) bolts. see scheme 1
3. Remove engine cover (1).
4. Remove the quick connect coupling cover of the fuel feed hose.
5. Using the Fuel Line Disconnect Tool (J 43178), disconnect the quick connect coupling of the fuel feed hose from the fuel feed pipe of the fuel rail. (Scheme 55) Use a shop towel to catch any remaining fuel that may leak.
6. Install the Fuel Pressure Gauge Adapter (J 42982) between the fuel feed pipe of the fuel rail and of the fuel feed hose.
7. Install Fuel Pressure Gauge (J 34730-1A) to fuel pressure gauge adapter, and tighten securely. (Scheme 56)
8. Connect negative battery cable. Tighten clamp bolt to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
9. Turn ignition switch to RUN position to pressurize the fuel system.
10. Turn ignition switch to OFF position.
11. Check for any fuel leaks.

1. Release the fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-153233-S42569625982003040800000).
2. Remove the Fuel Pressure Gauge (J 34730-1A) from the Fuel Pressure Gauge Adapter (J 42982).
3. Using the Fuel Line Disconnect Tool (J 43178), disconnect the quick connect coupling of the fuel pressure gauge adapter from the fuel feed pipe of the fuel rail. (Scheme 55) Use a shop towel to catch any remaining fuel that may leak.
4. Disconnect the quick connect coupling of the fuel feed hose from the fuel pressure gauge adapter, and remove the adapter. Use a shop towel to catch any remaining fuel that may leak.
5. Connect the quick-connect fitting of the fuel feed hose (1) to the fuel rail fuel feed pipe (2).
6. Install the cover for the quick connect coupling of the fuel feed hose.
7. Connect the negative battery cable. Tighten clamp bolt to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
8. Turn ignition switch to RUN position to pressurize the fuel system.
9. Turn ignition switch to OFF position.
10. Check for any fuel leaks.
11. Install engine cover (1). see scheme 1
12. Install engine cover (1) bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).

Scheme 55

Scheme 56

FUEL PRESSURE REGULATOR

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Fuel pressure regulator is located on fuel pump assembly in the fuel tank. Remove the fuel sender assembly. See «FUEL SENDER ASSEMBLY»(ref-153233-S08759715102003032700000).
2. Remove the bottom cap (2) and the lower cushion (3) from the fuel sender assembly. (Scheme 57)
3. Remove the fuel pressure regulator (1).

Scheme 57

1. To install, apply gasoline to NEW fuel pressure regulator "O" ring (1), and install onto fuel pressure regulator (2). (Scheme 57)
2. Install the fuel pressure regulator (1) into the fuel sender assembly. (Scheme 57)
3. Position the lower cushion (3) on bottom of fuel pump, and install the lower cap (2) to the sender assembly until the cap locks into place. (Scheme 57)
4. Install the fuel sender assembly to the fuel tank. See «FUEL SENDER ASSEMBLY»(ref-153233-S08759715102003032700000).

FUEL PUMP

Note. When servicing fuel pump, use care to cover all fuel line fittings and connections to prevent dirt from entering fuel pump or fuel lines.

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Remove the fuel sender assembly. See «FUEL SENDER ASSEMBLY»(ref-153233-S08759715102003032700000).
2. Remove the lower cap (9) and the lower cushion (8) from the fuel sender assembly. (Scheme 58)
3. Remove the fuel pressure regulator (6).
4. Disconnect the fuel level sensor harness connector.
5. Remove the fuel level sensor (3).
6. Remove the fuel sender top cap (2) from the fuel filter assembly.
7. Disconnect the fuel pump harness connector.
8. Remove the fuel pump (11) from the fuel filter assembly (13). (Scheme 58)
9. Remove the locking ring (10) for the fuel strainer from the fuel pump. (Scheme 58)

Scheme 58

1. Install the fuel pump strainer (7) to the fuel pump (11). Use a new locking ring (10). (Scheme 58)
2. Apply gasoline to fuel pump "O" ring (12), and install to the fuel pump.
3. Install the fuel pump (11) in to the fuel filter assembly (13). (Scheme 58)
4. Apply gasoline to fuel pressure regulator "O" ring (5), and install to the fuel pressure regulator (6).
5. Install the fuel pressure regulator in to the fuel filter assembly.
6. Connect fuel pump harness connector (4). Ensure connections are secure at the fuel pump and the top cap (2) of the sender assembly. (Scheme 58)
7. Install the fuel sender assembly top cap (2) to the fuel filter assembly (13). The fuel sender assembly end caps snap into place. (Scheme 58)
8. Install the fuel level sensor (3) to the fuel sender assembly.
9. Connect the fuel level sensor harness connector.
10. Position lower cushion (8) on bottom of fuel pump, and install lower cap (9) to fuel filter assembly. (Scheme 58)

FUEL RAILS & FUEL INJECTORS

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Remove engine cover (1) bolts. see scheme 1
2. Remove engine cover (1).
3. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-153233-S42569625982003040800000).
4. Remove the quick connect coupling cover.
5. Disconnect fuel feed hose coupling from the fuel feed pipe of the fuel rail using the Fuel Line Disconnect Tool (J 43178), or equivalent. (Scheme 55) Use a shop towel to catch any remaining fuel that may leak. See «QUICK CONNECT FITTING(S) SERVICE (METAL COLLAR)»(ref-153233-S25317093272003032700000).
6. Disconnect PCV hose (1) from PCV valve. (Scheme 34)
7. Disconnect PCV breather hose (2). (Scheme 34)
8. Disconnect EVAP hose (3). (Scheme 34)
9. Swing the 2 PCV hoses and EVAP hose away from the cylinder.
10. Remove the bolt to the ignition coil wire harness bracket.
11. Disconnect fuel injector harness connectors.
12. Remove the bolt (1) from fuel supply pipe bracket. (Scheme 59)
13. Remove the 2 bolts (4) from the fuel rail (3). (Scheme 59)
14. Remove fuel rail (3) and spacers (2) from the engine. (Scheme 59)
15. Remove the fuel injector with the "O" rings and the grommets from the fuel rail.

Scheme 59

1. Install NEW "O" rings (3) and new grommets (2) on the fuel injectors (1). (Scheme 60)
2. Apply clean engine oil to the "O" rings (3) and to the grommets (2).
3. Install the fuel injectors (1) into the fuel rail. (Scheme 59)
4. Install fuel rail (3) and spacers (2) onto the engine. (Scheme 59)
5. Install 2 fuel rail-to-engine bolts (4). Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
6. Install the bolt (1) to the fuel supply pipe bracket. Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
7. Connect fuel injector harness connectors.
8. Install the bolt to the ignition coil wire harness bracket. Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
9. Connect EVAP hose (3). (Scheme 34)
10. Connect PCV breather hose (2). (Scheme 34)
11. Connect PCV hose (1) to the PCV valve. (Scheme 34)
12. Connect the quick-connect fitting (1) for the fuel feed hose to the fuel feed pipe (2) of the fuel rail. (Scheme 61) See «QUICK CONNECT FITTING(S) SERVICE (METAL COLLAR)»(ref-153233-S25317093272003032700000).
13. Install the quick connect coupling cover.
14. Connect negative battery cable. Tighten clamp bolt to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
15. Turn ignition switch to RUN position to pressurize the fuel system.
16. Turn ignition switch to OFF position.
17. Inspect for fuel leaks.
18. Repair any fuel leaks as necessary.
19. Install engine cover (1).
20. Install engine cover (1) bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).

Scheme 60

Scheme 61

FUEL TANK

Note. The fuel tank equipped with On-Board Refueling Vapor Recovery (ORVR) components require special handling. Follow all instructions for servicing the fuel tank as specified in the service procedures. Damage to the fuel system components and the failure to meet the Federal Regulations may result from incorrect servicing of the fuel tank.

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Drain fuel tank into approved container.
2. Raise and support vehicle.
3. Remove catalytic converter and intermediate pipe assembly.
4. Remove 2 left side bolts (1) and 3 right side bolts (3) from the rear exhaust heat shield (2). (Scheme 62)
5. Remove rear exhaust heat shield (2) from the underbody.
6. Remove 2 bolts (1) securing the parking brake cable (2) on left side of vehicle. (Scheme 63)
7. Remove 2 bolts (1) securing the parking brake cable (2) on right side of vehicle. (Scheme 64)
8. Disconnect fuel supply line. See «QUICK CONNECT FITTING(S) SERVICE (PLASTIC COLLAR)»(ref-153233-S10122470382003032700000).
9. Loosen fuel filler hose clamp (1). (Scheme 65)
10. Disconnect fuel filler hose (2) from the fuel tank.
11. Disconnect filler pipe vent line (1) from fuel tank (2). (Scheme 66)
12. Disconnect the On-Board Refueling Vapor Recovery (ORVR) vent line (1) from the Fill Limiter Vent Valve (FLVV) by pinching both sides of the hose connector. (Scheme 67)
13. Disconnect the filler pipe vent line (1) from the FLVV (2). (Scheme 68)
14. Disconnect EVAP vapor line (1) from the EVAP canister by pinching both sides of the hose connector. (Scheme 69)
15. Support the fuel tank with a transmission jack or other suitable fixture.
16. Remove 4 bolts (1) and the 2 fuel tank straps (2). (Scheme 70)
17. Remove fuel tank (3).
18. If replacing the fuel tank, remove all lines, hoses, and the FLVV, and install on the replacement fuel tank.

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Scheme 70

1. Install fuel tank (3).
2. Install fuel tank straps (2) and the 4 bolts (1). Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). (Scheme 70)
3. Connect EVAP vapor line (1) to EVAP canister. (Scheme 69)
4. Connect filler pipe vent line (1) to the FLVV (2). (Scheme 68)
5. Connect ORVR vent line (1) to the FLVV. (Scheme 67)
6. Connect filler pipe vent line (1) to fuel tank (2). (Scheme 66)
7. Connect fuel filler hose (2) to the fuel tank.
8. Secure fuel filler hose (2) to the fuel tank with the hose clamp (1). (Scheme 65)
9. Connect fuel supply line.
10. Secure right side parking brake cable (2) with 2 bolts (1). Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). (Scheme 64)
11. Secure left side parking brake cable (2) with 2 bolts (1). Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). (Scheme 63)
12. Install rear exhaust heat shield (2).
13. Secure rear exhaust heat shield (2) with the 2 left side bolts (1) and 3 right side bolts (3). Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). (Scheme 62)
14. Install the catalytic converter and intermediate exhaust pipe assembly to the vehicle.
15. Lower vehicle.
16. Install fuel tank vapor line (2) to fuel sender fitting.
17. Install fuel supply line (3) to fuel sender fitting.
18. Secure fuel supply line (3) using the retaining clip (1).
19. Connect fuel sender harness connector (1) to fuel sender assembly.
20. Connect FTP sensor harness connector (2) to fuel sender assembly.
21. Add fuel to fuel tank.
22. Connect negative battery cable. Tighten clamp bolt to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
23. Turn ignition switch to RUN position to pressurize the fuel system and check for leaks.
24. Inspect butyl caulk seal for the fuel sender access panel. Replace any missing butyl caulk as necessary.
25. Install access panel to rear seat floor.
26. Relocate carpet under the seat and left sill plate area.
27. Install sill plate to left side door opening.
28. Install rear seat bottom cushion.

FUEL TANK PRESSURE SENSOR

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Remove the 2 rear seat cushion fasteners and swing the rear seat bottom cushion up and out of the way.
2. Remove sill plate from the left side door opening.
3. Fold back the carpet in order to maintain metal-to-metal contact while servicing the fuel sender assembly.
4. Remove the access panel for the fuel sender assembly from the rear seat floor. The panel is held in place by a butyl caulk seal.
5. Disconnect the fuel sender harness connector (1) from the fuel sender assembly. see scheme 59
6. Disconnect Fuel Tank Pressure (FTP) sensor (2) harness connector from the fuel sender assembly. see scheme 59
7. Remove FTP sensor retaining clip (2). (Scheme 71)
8. Remove FTP sensor (1) from the fuel sender assembly.

Scheme 71

1. Install FTP sensor (1) to fuel sender assembly.
2. Install FTP sensor retaining clip (2). (Scheme 71)
3. Connect fuel sender harness connector (1). see scheme 59
4. Connect FTP sensor harness connector (2). Inspect the butyl caulk seal for the fuel sender access panel. see scheme 59
5. Replace any missing butyl caulk as necessary.
6. Install access panel to rear seat floor.
7. Relocate carpet under the seat and left sill plate area.
8. Install sill plate to left side door opening.
9. Install rear seat bottom cushion.
10. Secure seat cushion using the 2 fasteners.

QUICK CONNECT FITTING(S) SERVICE (METAL COLLAR)

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-153233-S42569625982003040800000) .
2. Grasp both sides of the fitting. Twist the female connector 1/4 turn in each direction to loosen any dirt within the fitting.
3. Blow any dirt out of the fitting using compressed air.
4. Insert the Fuel Line Disconnect Tool (J 43178), or equivalent, into the female connector. Push the tool inward to release the locking tabs.
5. Pull the connection apart. If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end to prevent damage to the "O" ring sealing surface. Use a clean shop towel to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required.
6. Using a clean shop towel, wipe off the male pipe end.
7. Inspect both ends of the fitting for dirt and burrs. Clean or replace components if necessary.

1. Apply a few drops of clean engine oil onto the male pipe end.
2. Push both sides of the fitting together to cause the retaining tabs to snap into place.
3. After installation, pull both sides of the fitting to make sure the connection is secure.

QUICK CONNECT FITTING(S) SERVICE (PLASTIC COLLAR)

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Grasp both sides of the quick connect fitting and twist 1/4 turn in each direction to loosen any dirt.
2. Remove any dirt, dust, or other foreign material from the quick connect fitting with compressed air.
3. Squeeze the release tabs on the plastic retainer.
4. Pull the quick connect fuel fitting apart. Use a shop towel to catch any remaining fuel that may leak from the fuel line and 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 to ensure the connection is secure.

IGNITION SYSTEMS

IGNITION COIL

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Remove 4 bolts from the engine cover (1). see scheme 1
2. Remove engine cover (1).
3. Disconnect all ignition coil (2) harness connectors. (Scheme 72)
4. Remove mounting bolts (4) from the ignition coils. (Scheme 72)
5. Remove the bolts (2) securing the wiring harness (1).
6. Remove the wiring harness (1).
7. Remove the ignition coils (3).

Scheme 72

1. Install the ignition coils (3).
2. Install ignition coil mounting bolts (4). Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). (Scheme 72)
3. Install the wiring harness (1) and 2 harness retainer bolts (2). Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
4. Connect the ignition coil (3) wiring harness connectors (1). (Scheme 72)
5. Install engine cover (1). see scheme 1
6. Install engine cover (1) bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).

See KNOCK SENSOR under SENSORS & SWITCHES.

SPARK PLUG

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Remove the engine cover (1) bolts.
2. Remove engine cover (1).
3. Disconnect each ignition coil (3) wiring harness connector (1). (Scheme 72)
4. Remove the bolt (4) securing each ignition coil to the cylinder head cover. (Scheme 72)
5. Remove each ignition coil (3).
6. Remove spark plugs.
7. Inspect spark plugs for electrode wear, carbon deposits and insulator damage.

1. Replace the spark plugs every 90,000 mi (144,000 km).
2. Set the spark plug gap. Bend only the side electrode if necessary. See «SPARK PLUG TYPE»(ref-153233-S38449277132003032800000) and «SPARK PLUG SPECIFICATIONS»(ref-153233-S13323352542003032800000) tables. SPARK PLUG TYPE Application Spark Plug Type Spark Plug No. 1.8L Except HO Denso SK20R11 - - NGK IFR6A11 1.8L HO Denso SR16R11 - - NGK IFR5A11 SPARK PLUG SPECIFICATIONS Application Gap - In. (mm) Torque - Ft. Lbs. (N.m) 1.8L Except HO (1).040-.051 (1.02-1.30) 13 (18) 1.8L HO (2).040-.043 (1.02-1.10) 18 (25) (1) Maximum used spark plug gap - 0.051 in. (1.3 mm). (2) Maximum used spark plug gap - 0.047 in. (1.2 mm).
3. Install spark plugs. Tighten spark plugs as specified. See «SPARK PLUG SPECIFICATIONS»(ref-153233-S13323352542003032800000) table.
4. Install ignition coils (3). (Scheme 72)
5. Install ignition coil bolts (4). Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
6. Connect ignition coil harness connectors (1). (Scheme 72)
7. Install engine cover (1). see scheme 1
8. Install engine cover (1) bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).

EMISSION SYSTEMS & SUB-SYSTEMS

EVAP CANISTER

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Raise and support vehicle.
2. Disconnect On-Board Refueling Vapor Recovery (ORVR) vent line (1) from EVAP canister port by pinching both sides of the hose connector (1). (Scheme 73)
3. Disconnect EVAP vapor line (1) from EVAP canister port by pinching both sides of hose connector (1). (Scheme 74)
4. Disconnect 3 EVAP hoses (3) from EVAP canister (1). (Scheme 75)
5. Disconnect EVAP pressure switching solenoid harness connector.
6. Remove 3 bolts (2) and EVAP canister (1).
7. Inspect EVAP purge system for carbon particle contamination before replacing EVAP canister.

Scheme 73

Scheme 74

Scheme 75

1. Install EVAP canister (1) to vehicle underbody and secure with the 3 bolts (2).
2. Tighten the EVAP canister bracket support bolts (2) to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
3. Connect 3 EVAP hoses (3) to EVAP canister (1). (Scheme 75)
4. Connect EVAP pressure switching solenoid harness connector (4).
5. Connect EVAP vapor line (1) to EVAP canister port by pinching both sides of the hose connector (1). (Scheme 74)
6. Connect ORVR vent line (1) to EVAP canister port by pinching both sides of the hose connector (1). (Scheme 73)
7. Lower vehicle.

EVAP CANISTER VENT VALVE

See EVAP CANISTER VENT VALVE under MOTORS, RELAYS & SOLENOIDS.

See EVAP PRESSURE SWITCHING SOLENOID under MOTORS, RELAYS & SOLENOIDS.

CAMSHAFT ACTUATOR SYSTEM

See CAMSHAFT POSITION ACTUATOR SOLENOID VALVE under MOTORS, RELAYS & SOLENOIDS.

CAMSHAFT POSITION ACTUATOR SOLENOID VALVE FILTER

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Remove engine cover (1) bolts. see scheme 1
2. Remove engine cover (1). see scheme 1
3. Remove 2 bolts and generator support brace from the intake manifold.
4. Remove the bolt (3) that secures lower portion of breather pipe (1) of the Positive Crankcase Ventilation (PCV) system. (Scheme 41)
5. Remove 2 nuts (4) securing PCV breather pipe to cylinder head. (Scheme 41)
6. Disconnect PCV breather hose (2) from PCV breather pipe (1). (Scheme 41)
7. Remove PCV breather pipe.
8. Remove oil filter plug (3) from cylinder head. (Scheme 76)
9. Remove oil filter (2) from oil filter plug (1). (Scheme 77)

Scheme 76

Scheme 77

1. Install oil filter (2) into the oil filter plug (1). (Scheme 77)
2. Install oil filter plug (3) with a NEW "O" ring (2) into the cylinder head. (Scheme 76)
3. Tighten oil filter plug to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
4. Connect PCV breather hose (2) to PCV breather pipe (1). (Scheme 41)
5. Install PCV breather pipe (1), with a NEW gasket (5), to the cylinder head. (Scheme 41)
6. Install PCV breather pipe to cylinder head nuts (4). (Scheme 41) Tighten nuts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
7. Secure lower portion of PCV breather pipe (1) to intake manifold and install bolt (3). (Scheme 41) Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
8. Install generator support brace to intake manifold and install 2 bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
9. Install engine cover (1). see scheme 1
10. Install engine cover (1) bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). see scheme 1

See ROCKER ARM OIL CONTROL SOLENOID VALVE under MOTORS, RELAYS & SOLENOIDS.

ROCKER ARM OIL CONTROL SOLENOID VALVE FILTER

Note. The numbers in parenthesis in removal and installation procedures refer to numbered components in referenced figure(s).

1. Remove engine cover (1) bolts. see scheme 1
2. Remove engine cover (1). see scheme 1
3. Disconnect PCV hose (1) from PCV valve. (Scheme 34)
4. Disconnect PCV breather hose (2). (Scheme 34)
5. Disconnect EVAP hose (3). (Scheme 34)
6. Swing the 2 PCV hoses and EVAP hose away from the cylinder head.
7. Disconnect rocker arm oil pressure switch harness connector.
8. Disconnect rocker arm oil control solenoid (1) harness connector. (Scheme 78)
9. Remove 3 bolts (4) from rocker arm oil control solenoid housing (2). (Scheme 78)
10. Remove 2 nuts (3), rocker arm oil control solenoid housing (2) and gasket from the cylinder head. (Scheme 78)
11. Remove oil filter (1) from the oil passage in the cylinder head. (Scheme 79)

Scheme 78

Scheme 79

1. Install the oil filter (1) of the rocker arm oil control solenoid valve into the oil supply passage of the cylinder head. (Scheme 79)
2. Install rocker arm oil control solenoid housing (2) with NEW gasket to the cylinder head. (Scheme 78)
3. Install rocker arm oil control solenoid housing nuts (3) and 3 bolts (4). (Scheme 78) Tighten nuts/bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
4. Connect rocker arm oil control solenoid (1) harness connector. (Scheme 78)
5. Connect rocker arm oil pressure switch harness connector.
6. Connect PCV hose (1) and PCV breather hose (2) to the engine. (Scheme 34)
7. Connect EVAP hoses.
8. Install engine cover (1). see scheme 1
9. Install engine cover (1) bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000). see scheme 1

See ROCKER ARM OIL PRESSURE SWITCH under SENSORS & SWITCHES.