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

Removal & Installation 6 illustrations ~778 words

THROTTLE BODY ASSEMBLY

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

  1. Remove engine cover (1) bolts. (Scheme 1)
  2. Remove engine cover (1).
  3. Remove air inlet duct (2) from the throttle body assembly (1). (Scheme 2)
  4. Remove Positive Crankcase Ventilation (PCV) breather hose (6). (Scheme 2)
  5. Remove Throttle Position (TP) sensor harness connector (4). (Scheme 2)
  6. Rotate throttle lever and disconnect the accelerator cable and the throttle valve cable, if equipped.
  7. Disconnect Idle Air Control (IAC) valve harness connector (5).
  8. Drain the cooling system into appropriate container.
  9. Remove 2 coolant hoses (3) from throttle body.
  10. Remove 2 throttle body nuts (3) and accelerator control cable bracket (4). (Scheme 3)
  11. Remove 2 throttle body bolts (5).
  12. Remove throttle body (2) and gasket (1) from the intake manifold.
  13. Clean any remaining throttle body gasket (1) from the intake manifold.

Scheme 1

Scheme 1
Scheme 1

Scheme 2

Scheme 2
Scheme 2

Scheme 3

Scheme 3
Scheme 3
  1. Install a NEW throttle body gasket (1).
  2. Install throttle body (2) onto intake manifold. Install 2 bolts (5).
  3. Install the accelerator cable bracket (4) and 2 nuts (3) to throttle body. (Scheme 3)
  4. Tighten throttle body bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
  5. Connect coolant hoses (3) to throttle body. (Scheme 2)
  6. Connect PCV breather hose (6) to throttle body (1). (Scheme 2)
  7. Connect IAC valve harness connector (5). (Scheme 2)
  8. Connect TP sensor harness connector (4). (Scheme 2)
  9. Install air inlet duct (2). (Scheme 2)
  10. Refill the cooling system.
  11. Install engine cover (1). (Scheme 1)
  12. Install engine cover (1) bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).

FUEL SENDER ASSEMBLY

WARNINGGasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. Provide proper ventilation when working with fuel in enclosed areas where fuel vapors can collect. The lack of adequate ventilation may result in personal injury.
WARNINGRemove the rear compartment floor trim to provide technician contact with the vehicle's metal surfaces. Failure to remove the rear compartment floor trim may cause a static electricity discharge to ignite any fuel vapor resulting in personal injury and vehicle damage.
WARNINGFuel Vapors can collect while servicing fuel system parts in enclosed areas such as a trunk. To reduce the risk of fire and increased exposure to vapors, use forced air ventilation such as a fan set outside of the trunk. Plug or cap any fuel system openings to reduce fuel vapor formation. Clean up any spilled fuel immediately. Avoid sparks and any source of ignition. Use signs to alert others in the work area that fuel system work is in process. Always wear safety goggles when working with fuel to protect the eyes from fuel splash.

Note. Cap the fittings and plug the holes when servicing the fuel system to prevent dirt and other contaminants from entering the open pipes and passages. Clean the fuel pipe connections, hose connections and areas surrounding the connections before performing any disconnections to avoid possible contamination in the system.

Note. Always replace the fuel sender assembly "O" rings when reinstalling the fuel sender assembly. Always maintain cleanliness when servicing fuel system components. Do not bend the arm of the fuel gage float while removing the fuel sender assembly.

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. Remove the 2 fasteners and swing the rear seat bottom cushion up and out of the way.
  3. Remove the sill plate from the left side door opening.
  4. Fold back the carpet in order to maintain metal-to-metal contact while servicing the fuel sender assembly.
  5. 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.
  6. Disconnect the fuel sender harness connector (1) from the fuel sender assembly. (Scheme 4)
  7. Disconnect the harness connector of the Fuel Tank Pressure (FTP) sensor (2) from the fuel sender assembly. (Scheme 4)
  8. Remove retaining clip (1) from the fuel line fitting. (Scheme 5)
  9. Remove fuel line (3) from the fuel sender assembly. (Scheme 5)
  10. Disconnect fuel tank vapor line (2) from fuel sender assembly.
  11. Remove 8 fuel sender assembly hold-down plate (2) bolts (1). (Scheme 6)
  12. Remove the hold-down plate (2).
  13. Clean the fuel pipe and the fuel sender assembly to prevent possible fuel contamination during removal.
  14. Remove the fuel sender assembly (4) from the fuel tank.
  15. Inspect and clean "O" ring sealing surfaces on the fuel sender assembly.

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6

Note. Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware. Do not repair sections of fuel pipes.

  1. Position NEW fuel sender assembly "O" ring (3) on the fuel sender assembly. (Scheme 6)
  2. Install fuel sender assembly (4) into the fuel tank.
  3. Install the fuel sender assembly hold-down plate (2). (Scheme 6)
  4. Install 8 hold-down plate bolts (1). Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153233-S09576916932003032600000).
  5. Install the fuel tank vapor line (2) to the fuel sender fitting. (Scheme 5)
  6. Install the fuel pipe (3) to the fuel sender fitting.
  7. Secure the fuel pipe (3) using the retaining clip (1). (Scheme 5)
  8. Connect the fuel sender harness connector (1) to the fuel sender assembly. (Scheme 4)
  9. Connect the FTP sensor harness connector (2) to the fuel sender assembly. (Scheme 4)
  10. Connect the negative battery cable.
  11. Pressurize the fuel system and check for leaks.
  12. Inspect butyl caulk seal for the fuel sender access panel. Replace any missing butyl caulk as necessary.
  13. Install access panel to rear seat floor.
  14. Relocate carpet under the seat and left sill plate area.
  15. Install sill plate to left side door opening.
  16. Install rear seat bottom cushion.
  17. Secure seat cushion using the 2 fasteners.

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