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Engine Control System - 1.8L (Lnk) - Introduction: Removal & Installation Pontiac Vibe I рестайлинг

Testing & Diagnostics ~8972 words

Removal Procedure

Note. Check the resistance values of all PCM relays, solenoids, and other output controls before replacing or substituting the Powertrain Control Module (PCM). Check all the sensor wiring and the PCM output control circuits for a short to ground before replacing or substituting the PCM. Perform all circuit repairs or malfunctioning component part replacements before installing a replacement or substitute PCM. This will prevent damage to the replacement or substitute PCM.

Note. Do not touch the connector pins or soldered components on the circuit board in order to prevent possible electrostatic discharge (ESD) damage to the PCM.

Note. Turn the ignition OFF 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.) in order to prevent internal PCM damage.

IMPORTANTService 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.
  1. Disconnect the battery. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200056-S05052159252005102000000) in Engine Electrical.
  2. Remove the two retainers from the PCM close out panel (1) below the instrument panel (IP) compartment door.
  3. Swing the PCM close out panel (1) down.
  4. Open the IP compartment.
  5. Push in on both sides of the IP compartment in order to release the safety catches.
  6. Remove the IP compartment door assembly from the IP.
  7. Remove the two PCM bracket fasteners.
  8. Pull the PCM (2) with brackets (3) toward you and swing both down away from under the IP.
  9. Disconnect the four PCM electrical connectors (1).
  10. Remove the four fasteners and the two brackets (3) from the PCM (2).

Installation Procedure

Note. Do not touch the connector pins or soldered components on the circuit board in order to prevent possible electrostatic discharge (ESD) damage to the PCM.

Note. Turn the ignition OFF 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.) in order to prevent internal PCM damage.

  1. Install the two PCM brackets (3) to the PCM (2).
  2. Secure the two brackets to the PCM with the four fasteners. Tighten: Tighten the PCM bracket fasteners to 3.2 N.m (28 lb in).
  3. Connect the four PCM electrical connectors (1).
  4. Swing the PCM (2) with bracket (3) up in position under the IP.
  5. Secure the PCM to the IP with the two fasteners. Tighten: Tighten the two fasteners to 9 N.m (80 lb in).
  6. Install the IP compartment door into the IP.
  7. Push in on both sides of the IP compartment in order to release the safety catches and close the door.
  8. Swing the close out panel (1) up under the PCM and secure with the two retainers.
  9. Connect the battery. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200056-S05052159252005102000000) in Engine Electrical.
  10. Program the vehicle identification number (VIN) to the replacement PCM. Refer to «Control Module References»(ref-200102-S05820283132005102000000) in Computer/Integrating Systems.
IMPORTANTUse care when handling the engine coolant temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system.
  1. Drain the engine coolant. Refer to «Draining and Filling Cooling System»(ref-200120-S08195956722005102000000) in Engine Cooling.
  2. Disconnect the ECT sensor electrical connector (1) from the ECT sensor (2) located next to the upper radiator hose on the cylinder head.
  3. Remove the ECT sensor (2) from the cylinder head.
  1. Install the ECT sensor (2) into cylinder head. Tighten: Tighten the ECT sensor to 20 N.m (14 lb ft).
  2. Connect the ECT sensor electrical connector (1).
  3. Refill the engine coolant. Refer to «Draining and Filling Cooling System»(ref-200120-S08195956722005102000000) in Engine Cooling.

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.

  1. Disconnect the electrical connector (1) from the mass air flow (MAF) sensor (4).
  2. Remove the two fasteners.
  3. Remove the MAF sensor (4) from the air cleaner housing (2).
  4. Remove the O-ring (3).
  1. Install a new O-ring (3) on the MAF sensor.
  2. Install the MAF sensor (4) into the air cleaner housing (2).
  3. Secure the MAF sensor to the air cleaner housing with the 2 fasteners. Tighten: Tighten the 2 fasteners to 2 N.m (18 lb in).
  4. Connect the MAF sensor electrical connector (1).
  1. Disconnect the electrical connector (1) from the mass air flow (MAF) sensor (4).
  2. Remove the two fasteners.
  3. Remove the MAF sensor (4) from the air cleaner housing (2).
  4. Remove the O-ring (3).
  1. Install a new O-ring (3) on the MAF sensor.
  2. Install the MAF sensor (4) into the air cleaner housing (2).
  3. Secure the MAF sensor to the air cleaner housing with the 2 fasteners. Tighten: Tighten the 2 fasteners to 2 N.m (18 lb in).
  4. Connect the MAF sensor electrical connector (1).

Note. The heated oxygen sensors each use a permanently attached pigtail and connector. Do not remove the pigtail from the heated oxygen sensor. Damage or removal of the pigtail or the connector affects proper operation of the heated oxygen sensor. Handle the oxygen sensor carefully. Do not drop the oxygen sensor. Keep the in-line connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, the connector, or the terminals. Replace the oxygen sensor if the pigtail wiring, the terminals, or the connector is damaged. Proper oxygen sensor operation requires an external air reference. This external air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, the connectors, or the terminals results in the obstruction of the air reference and degrades the oxygen sensor performance. A dropped oxygen sensor is a bad oxygen sensor.

IMPORTANTThe HO2S may be difficult to remove at temperatures exceeding 48°C (120°F). 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.
  1. Remove the carpet retaining pin (1) from the front floor console (3).
  2. Pull back the carpet (2) from the area near the front floor console (3).
  3. Disconnect the HO2S 1 electrical connector (1).
  4. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200076-S37188174922005102000000) in General Information.
  5. Remove the HO2S 1 wiring pigtail and body plug (1) from the floor pan.
  6. Remove the HO2S 1 (2) from the exhaust pipe.
IMPORTANTThe HO2S 1 comes with an anti-seize coating on the new sensor. Take precautions in order to prevent removal of any of this coating prior to installation.
  1. Install the HO2S 1 (2) into the exhaust pipe.
  2. Tighten the HO2S 1. Tighten: Tighten the HO2S 1 to 44 N.m (32 lb ft).
  3. Install the HO2S 1 wiring pigtail and body plug (1) into the floor pan.
  4. Lower the vehicle.
  5. Connect the HO2S 1 electrical connector.
  6. Install the carpet (2) around the front floor console (3).
  7. Secure the carpet to the front floor console with the retaining pin (1).

Note. The heated oxygen sensors each use a permanently attached pigtail and connector. Do not remove the pigtail from the heated oxygen sensor. Damage or removal of the pigtail or the connector affects proper operation of the heated oxygen sensor. Handle the oxygen sensor carefully. Do not drop the oxygen sensor. Keep the in-line connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, the connector, or the terminals. Replace the oxygen sensor if the pigtail wiring, the terminals, or the connector is damaged. Proper oxygen sensor operation requires an external air reference. This external air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, the connectors, or the terminals results in the obstruction of the air reference and degrades the oxygen sensor performance. A dropped oxygen sensor is a bad oxygen sensor.

IMPORTANTThe HO2S may be difficult to remove at temperatures exceeding 48°C (120°F). 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.
  1. Remove the rear floor console in order to gain access to the HO2S 2 electrical connector. Refer to «Console Replacement - Rear Floor»(ref-200060-S06704105932005102000000) in Instrument Panel, Gages, and Console.
  2. Disconnect the HO2S 2 electrical connector (1).
  3. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200076-S37188174922005102000000) in General Information.
  4. Remove the HO2S 2 wiring pigtail and body plug (1) from the floor pan.
  5. Remove the HO2S 2 (2) from the exhaust pipe.
IMPORTANTThe HO2S 2 comes with an anti-seize coating on the new sensor. Take precautions in order to prevent removal of any of this coating prior to installation.
  1. Install the HO2S 2 (2) into the exhaust pipe.
  2. Tighten the HO2S 2. Tighten: Tighten the HO2S 2 to 44 N.m (32 lb ft).
  3. Install the HO2S 2 wiring pigtail and body plug (1) into the floor pan.
  4. Lower the vehicle.
  5. Connect the HO2S 2 electrical connector (1).
  6. Install the rear floor console. Refer to «Console Replacement - Rear Floor»(ref-200060-S06704105932005102000000) in Instrument Panel, Gages, and Console.

Note. The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent as damage may result.

  1. Remove the inlet air duct from between the air cleaner and throttle body.
  2. Remove the 2 fasteners (3) from the throttle position (TP) sensor (2).
  3. Remove the TP sensor (2) from the throttle body.
  1. Align the throttle shaft (3) with the slot in the TP sensor (2).
  2. Install the TP sensor (2) to the throttle body (1).
  3. Secure the TP sensor with the 2 fasteners (3). Tighten: Tighten the fasteners to 2.0 N.m (18 lb in).
  4. Install the inlet air duct to the air cleaner and the throttle body.
  1. Disconnect the electrical connector (2) to the idle air control (IAC) valve (1).
  2. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-200120-S08195956722005102000000) in Engine Cooling.
  3. Disconnect the two coolant hoses (2) to the IAC valve.
  4. Remove the fasteners retaining the IAC valve (3).
  5. Remove the IAC valve (4) from the throttle body (1).
  6. Remove any remaining IAC valve gasket (4).
  1. Install a new IAC valve gasket (4).
  2. Install the IAC valve (3) to the throttle body.
  3. Install the fasteners that retain the IAC valve. Tighten: Tighten the fasteners to 3.7 N.m (33 lb in).
  4. Connect the two coolant hoses (2) to the IAC valve.
  5. Connect the electrical connector (2) to the IAC valve (1).
  6. Refill the cooling system. Refer to «Draining and Filling Cooling System»(ref-200120-S08195956722005102000000) in Engine Cooling.
  1. Remove the 4 fasteners from the engine cover (1).
  2. Remove the engine cover (1) from the engine.
  3. Remove the air inlet duct (2) from the throttle body assembly (1).
  4. Remove the positive crankcase ventilation (PCV) breather hose (6).
  5. Remove the throttle position (TP) sensor connector (4).
  6. Rotate the throttle lever and disconnect the accelerator cable and the throttle valve cable, if equipped.
  7. Disconnect the electrical connector (5) of the idle air control (IAC) valve.
  8. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-200120-S08195956722005102000000) in Engine Cooling.
  9. Remove the 2 coolant hoses (3) from the throttle body.
  10. Remove the 2 throttle body nuts (3) and the accelerator control cable bracket (4).
  11. Remove the 2 throttle body bolts (5).
  12. Remove the throttle body (2) and the gasket (1) from the intake manifold.
  13. Clean any remaining throttle body gasket (1) from the intake manifold.
  1. Install a new throttle body gasket (1).
  2. Install the throttle body (2) onto the intake manifold with the 2 bolts (5).
  3. Install the accelerator cable bracket (4) and the 2 nuts (3) to the throttle body.
  4. Tighten the 4 throttle body fasteners. Tighten: Tighten the fasteners to 22 N.m (16 lb ft).
  5. Connect the 2 coolant hoses (3) to the throttle body.
  6. Connect the PCV breather hose (6) to the throttle body (1).
  7. Connect the IAC valve electrical connector (5).
  8. Connect the TP sensor electrical connector (4).
  9. Install the air inlet duct (2).
  10. Refill the cooling system. Refer to «Draining and Filling Cooling System»(ref-200120-S08195956722005102000000) in Engine Cooling.
  11. Install the engine cover (1) to the engine.
  12. Secure the engine cover (1) with the 4 fasteners. Tighten: Tighten the fasteners to 7 N.m (62 lb in).
  1. Relieve the fuel pressure. Refer to «Fuel Pressure Relief Procedure»(ref-200095-S29986787282005102000000) .
  2. Remove the four fasteners from the engine cover (1).
  3. Remove the engine cover (1) from the engine.
  4. Remove the quick connect coupling cover of the fuel feed hose.
  5. Using the J 43178 , disconnect the quick connect coupling of the fuel feed hose from the fuel feed pipe of the fuel rail. Use a shop towel in order to catch any remaining fuel that may leak. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-200095-S25812448662005102000000) .
  6. Install the J 42982 between the fuel feed pipe of the fuel rail and of the fuel feed hose.
  7. Install the J 34730-1A to the J 42982 , and tighten securely.
  8. Connect the negative battery cable. Tighten: Tighten the retainer for the negative battery cable terminal to 15 N.m (11 lb ft).
  9. Turn ON the ignition in order to pressurize the fuel system.
  10. Turn OFF the ignition.
  11. Check for any fuel leaks.
  1. Relieve the fuel pressure. Refer to the «Fuel Pressure Relief Procedure»(ref-200095-S29986787282005102000000) .
  2. Remove the J 34730-1A from the J 42982 .
  3. Using the J 43178 , disconnect the quick connect coupling of the J 42982 from the fuel feed pipe of the fuel rail. Use a shop towel in order to catch any remaining fuel that may leak.
  4. Disconnect the quick connect coupling of the fuel feed hose from the J 42982 and remove the adapter. Use a shop towel in order to catch any remaining fuel that may leak.
  5. Connect the quick-connect fitting of the fuel feed hose (1) to the fuel feed pipe (2) of the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-200095-S25812448662005102000000) .
  6. Install the cover for the quick connect coupling of the fuel feed hose.
  7. Connect the negative battery cable. Tighten: Tighten the retainer for the negative battery cable terminal to 15 N.m (11 lb ft).
  8. Turn ON the ignition in order to pressurize the fuel system.
  9. Turn OFF the ignition.
  10. Check for any fuel leaks.
  11. Install the engine cover (1) to the engine.
  12. Secure the engine cover (1) with the four fasteners. Tighten: Tighten the fasteners to 7 N.m (62 lb in).
IMPORTANTBefore servicing fuel system connections, relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  1. Grasp both sides of the fitting. Twist the female connector 1/4 turn in each direction in order to loosen any dirt within the fitting.
  2. Blow any dirt out of the fitting using compressed air.
  3. Insert the J 43178 tool into the female connector. Push the tool inward in order to release the locking tabs.
  4. Pull the connection apart.
  5. Using a clean shop towel, wipe off the male pipe end.
  6. Inspect both ends of the fitting for dirt and for burrs. Clean or replace the 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 in order 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.
  1. Grasp both sides of the quick connect fitting and twist 1/4 turn in each direction in order 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 the fitting.
  1. Apply a few drops of clean engine oil to the end of the male fuel pipe.
  2. Insert the male fuel pipe into the quick connect fitting.
  3. Push both sides of the quick connect fitting together until the fitting clicks.
  4. Pull and push repeatedly on both sides of the quick connect fitting in order to ensure that the connection is secure.
CAUTIONProvide additional support when a vehicle is on a hoist in the following ways: Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off. Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off. Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.

Note. The fuel tank equipped with 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.

  1. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-200094-S22519026582005102000000) .
  2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200076-S37188174922005102000000) in General Information.
  3. Remove the catalytic converter and intermediate pipe assembly from the vehicle. Refer to «Catalytic Converter Replacement (LNK Engine)»(ref-200084-S26932355542005102000000) in Engine Exhaust.
  4. Remove the 2 left side bolts (1) and the 3 right side bolts (3) from the rear exhaust heat shield (2).
  5. Remove the rear exhaust heat shield (2) from the underbody.
  6. Remove the 2 bolts (1) securing the parking brake cable (2) on the right side of the vehicle.
  7. Disconnect the fuel supply line. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200094-S27544717142005102000000) .
  8. Disconnect the fuel tank vapor line with the quick release fitting from the fuel vapor pipe. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200094-S27544717142005102000000) .
  9. Loosen the fuel filler hose clamp (1).
  10. Disconnect the fuel filler hose (2) from the fuel tank.
  11. Disconnect the on-board refueling vapor recovery (ORVR) vent line from the fill limiter vent valve (FLVV) of the evaporative emission (EVAP) canister. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200094-S27544717142005102000000) .
  12. Remove the 4 bolts (1) and the 2 fuel tank straps (2) from the vehicle.
  13. Remove the fuel tank (3) from the vehicle. If replacing the fuel tank, remove all lines and hoses, and install on the replacement fuel tank.
  1. Install the fuel tank (3) to the vehicle.
  2. Install the 2 fuel tank straps (2) to the vehicle with the 4 bolts (1). Tighten: Tighten the bolts to 39 N.m (29 lb ft).
  3. Connect the fuel filler hose (2) to the fuel tank.
  4. Secure the fuel filler hose (2) to the fuel tank with the hose clamp (1).
  5. Connect the fuel supply line. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200094-S27544717142005102000000) .
  6. Connect the fuel tank vapor line with the quick release fitting to the fuel vapor pipe. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200094-S27544717142005102000000) .
  7. Connect the ORVR vent line to the FLVV on the EVAP canister.
  8. Secure the parking brake cable (2) on the right side of the vehicle with 2 bolts (1). Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
  9. Install the rear exhaust heat shield (2) to the vehicle underbody.
  10. Secure the rear exhaust heat shield (2) with the 2 left side bolts (1) and the 3 right side bolts (3). Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
  11. Install the catalytic converter and intermediate exhaust pipe assembly to the vehicle. Refer to «Catalytic Converter Replacement (LNK Engine)»(ref-200084-S26932355542005102000000) in Engine Exhaust.
  12. Lower the vehicle.
  13. If the fuel sender assembly was removed, refer to «Fuel Sender Assembly Replacement (FWD)»(ref-200094-S00528292382005102000000) or «Fuel Sender Assembly Replacement (AWD)»(ref-200094-S34295836252005102000000) .
  14. Connect the ORVR vent line (2) to the fuel sender assembly (1).
  15. Slide the
  16. Slide the quick connect clasp (1) into the lock position on the ORVR vent line (2).
  17. Connect the fuel supply line (1) to the fuel sender assembly.
  18. Secure the fuel supply line (2) to the sender assembly with the retaining clip (1).
  19. Connect the fuel sender electrical connector (2) to the fuel sender assembly.
  20. Add fuel to the fuel tank.
  21. Connect the negative battery cable. Tighten: Tighten the retainer for the negative battery cable terminal to 15 N.m (11 lb ft).
  22. Pressurize the fuel system and check for leaks.
  23. Install the access panel (1) to the rear seat floor panel (3).
  24. Secure the access panel to the body with 4 bolts. Tighten: Tighten the 4 bolts to 6 N.m (53 lb in).
  25. Relocate the carpet under the ride side seat area and the right sill plate area.
  26. Install the sill plate to the right side door opening.
  27. Lower the rear seat bottom cushion (1) and secure with 2 bolts (2). Tighten: Tighten the 2 bolts to 41 N.m (30 lb ft).
  1. Remove the fuel sender assembly (2) from the fuel tank. Refer to «Fuel Sender Assembly Replacement»(ref-200095-S34480041992005102000000) .
  2. Disconnect the fuel pump and fuel level sensor (1) electrical connectors.
  3. Compress the assembly spring (1) and remove the E-clip (2) from the guide post of the fuel sender assembly upper support.
  4. Release the lock tab (1) of the fuel pump transfer jet tube (2) and disconnect the tube from the lower housing.
  5. Release the two lock tabs (1) securing the fuel pump and filter assembly to the lower housing.
  6. Separate the upper support and fuel pump filter assembly (1) from the lower housing (2).
  7. Disconnect the fuel pump electrical connector (1).
  8. Use a screwdriver with a tape protected end (3) in order to release the 5 lock tabs (1, 2) from the fuel pump strainer assembly.
  9. Remove the fuel pump (1) from the fuel filter assembly (3).
  10. If replacing the fuel filter (3), remove the fuel pressure regulator (2) from the fuel filter assembly (3). Refer to «Fuel Pressure Regulator Replacement»(ref-200095-S33351885272005102000000) .
  1. Lubricate all O-rings (4,11) with fuel during assembly. Use the exploded view to aid in assembly.
  2. Install a new O-ring (1) into the fuel pump (2).
  3. Install the fuel pump (1) into the fuel filet assembly (2).
  4. Connect the fuel pump electrical connector (1).
  5. Align the two lock tabs (2) with the fuel pressure regulator (1) and install the fuel pump strainer assembly (3) onto the fuel filter assembly (4).
  6. Secure the strainer assembly to the filter assembly with the 5 lock tabs (1, 2, 3).
  7. Install the lower housing (2) to the fuel pump filter and upper support assemblies (1).
  8. Secure the lower and upper assemblies using the two lock tabs (1)
  9. With the upper support guide posts correctly aligned with lower housing, gently compress the spring (1) and install a new E-clip (2).
  10. Connect the jet tube (2) to the lower housing fuel inlet port (1) and secure with the lock tab.
  11. Connect the fuel pump and fuel level sensor (1) electrical connectors.
  12. Install the fuel sender assembly into the fuel tank. Refer to «Fuel Sender Assembly Replacement»(ref-200095-S34480041992005102000000) .
CAUTIONGasoline 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.
CAUTIONProvide proper ventilation when working with fuel in enclosed areas where fuel vapors can collect. The lack of adequate ventilation may result in personal injury.
CAUTIONAlways wear safety goggles when working with fuel in order to protect the eyes from fuel splash.
CAUTIONRemove 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.
CAUTIONFuel 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 in order 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.

Note. Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

Note. Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections The hose connections The areas surrounding the connections

IMPORTANTAlways 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.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-200095-S29986787282005102000000) .
  2. Remove the 2 fasteners (2) of the right side cushion (1) and swing the rear seat bottom cushion (1) up and out of the way.
  3. Remove the sill plate from the right 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 4 fasteners to the access panel (1) for the fuel sender assembly from the rear seat floor (3).
  6. Lift the access panel (1) and disconnect the fuel sender electrical connector (2) from the fuel sender assembly.
  7. Remove the retaining clip (1) from the fuel line fitting (2).
  8. Disconnect the fuel line (1) from the fuel sender assembly.
  9. Unlock the quick connect fitting of the on-board refueling vapor recovery (ORVR) vent line by sliding the lock clasp (1) to unlock position.
  10. Disconnect the ORVR vent line (2) from the fuel sender assembly (1).
  11. Use the CH-47717 (1) in order to loosen the fuel sender assembly lock ring.
  12. Clean the area around the fuel and vent lines and the fuel sender assembly in order to prevent possible fuel contamination during removal.
  13. Locate the 4 safety latches (1, 3) and the safety stop (2) on the fuel sender assembly lock ring.
  14. While rotating the lock ring during removal, ensure that each safety latch is gently depressed in order to pass without engaging the safety stop.
  15. Remove the lock ring (1).
  16. Remove the fuel sender assembly (2) from the fuel tank.

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. Install a new O-ring seal (1) onto the fuel tank.
  2. Install the fuel sender assembly (2) into the fuel tank through the floor panel opening (3).
  3. Align the notch (1) on the fuel sender assembly with the slot (2) in the fuel tank opening.
  4. Align the extra ridge (1) on the fuel tank lock ring with the mark (2) on the fuel tank.
  5. Gently push down on the fuel sender while rotating the lock ring onto the fuel tank.
  6. Use the CH-47717 (1) in order to tighten the fuel sender assembly lock ring.
  7. After 2 full rotations of the lock ring, watch for the alignment of the lock ring extra ridge (1) with the 2 triangle marks (2) on the fuel tank.
  8. Rotate the lock ring until the ridge (1) is positioned within the 16 degree area (3) between the 2 marks (2).
  9. Connect the ORVR vent line (2) to the fuel sender assembly (1).
  10. Slide the quick connect clasp (1) into the lock position on the ORVR vent line (2).
  11. Connect the fuel supply line (1) to the fuel sender assembly.
  12. Secure the fuel supply line (2) to the sender assembly with the retaining clip (1).
  13. Connect the fuel sender electrical connector (2) to the fuel sender assembly.
  14. Add fuel to the fuel tank.
  15. Connect the negative battery cable. Tighten: Tighten the retainer for the negative battery cable terminal to 15 N.m (11 lb ft).
  16. Pressurize the fuel system and check for leaks.
  17. Install the access panel (1) to the rear seat floor panel (3).
  18. Secure the access panel to the body with 4 bolts. Tighten: Tighten the 4 bolts to 6 N.m (53 lb in).
  19. Relocate the carpet under the ride side seat area and the right sill plate area.
  20. Install the sill plate to the right side door opening.
  21. Lower the rear seat bottom cushion (1) and secure with 2 bolts (2). Tighten: Tighten the 2 bolts to 41 N.m (30 lb ft).
  1. Remove the four fasteners from the engine cover (1).
  2. Remove the engine cover (1) from the engine.
  3. Relieve the fuel pressure. Refer to «Fuel Pressure Relief Procedure»(ref-200095-S29986787282005102000000) .
  4. Remove the quick connect coupling cover.
  5. Disconnect the coupling for the fuel feed hose from the fuel feed pipe of the fuel rail using the J 43178 . Use a shop towel in order to catch any remaining fuel that may leak. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-200095-S25812448662005102000000) .
  6. Disconnect the PCV hose (1) from the PCV valve.
  7. Disconnect the PCV breather hose (2).
  8. Disconnect the EVAP hose (3).
  9. Swing the two PCV hoses and the EVAP hose away from the cylinder head
  10. Remove the bolt to the ignition coil wire harness bracket.
  11. Disconnect the electrical connectors to the four fuel injectors.
  12. Remove the fastener (1) from the fuel supply pipe bracket.
  13. Remove the two fasteners (4) from the fuel rail (3).
  14. Remove the fuel rail (3) and the spacers (2) from the engine.
  15. Remove the fuel injector with the O-rings and with the grommets from the fuel rail.

Installation Procedures

  1. Install new O-rings (3) and new grommets (2) on the fuel injectors (1).
  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.
  4. Install the fuel rail (3) and the spacers (2) onto the engine.
  5. Secure the fuel rail to the engine with the 2 fasteners (4). Tighten: Tighten the fasteners to 29 N.m (21 lb ft).
  6. Install the fastener (1) to the fuel supply pipe bracket. Tighten: Tighten the fastener to 9 N.m (80 lb in).
  7. Connect the electrical connectors to the four fuel injectors.
  8. Install the bolt to the ignition coil wire harness bracket. Tighten: Tighten the fastener to 10 N.m (89 lb in).
  9. Connect the EVAP hose (3).
  10. Connect the PCV breather hose (2).
  11. Connect the PCV hose (1) to the PCV valve.
  12. Connect the quick-connect fitting (1) for the fuel feed hose to the fuel feed pipe (2) of the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-200095-S25812448662005102000000) .
  13. Install the quick connect coupling cover.
  14. Connect the negative battery cable. Tighten: Tighten the retainer for the negative battery cable terminal to 15 N.m (11 lb ft).
  15. Turn ON the ignition in order to pressurize the fuel system.
  16. Turn OFF the ignition.
  17. Inspect for fuel leaks.
  18. Repair any fuel leaks as necessary.
  19. Install the engine cover (1) to the engine.
  20. Secure the engine cover (1) with the four fasteners. Tighten: Tighten the fasteners to 7 N.m (62 lb in).
  1. Remove the fuel sender assembly (2) from the fuel tank. Refer to «Fuel Sender Assembly Replacement»(ref-200095-S34480041992005102000000) .
  2. Disconnect the fuel pump and fuel level sensor (1) electrical connectors.
  3. Compress the assembly spring (1) and remove the E-clip (2) from the guide post of the fuel sender assembly upper support.
  4. Release the lock tab (1) of the fuel pump transfer jet tube (2) and disconnect the tube from the lower housing.
  5. Release the 2 lock tabs (1) securing the fuel pump and filter assembly to the lower housing.
  6. Separate the upper support and fuel pump filter assembly (1) from the lower housing (2).
  7. Use a screwdriver with a tape protected end (3) in order to release the 5 lock tabs (1, 2) from the fuel pump strainer assembly.
  8. Remove the fuel pressure regulator (1) from the fuel filter assembly (2).
  1. Apply gasoline to fuel pressure regulator O-rings (1).
  2. Install the fuel pressure regulator (1) into the fuel filter assembly (2).
  3. Align the 2 lock tabs (2) with the fuel pressure regulator (1) and install the fuel pump strainer assembly (3) onto the fuel filter assembly (4).
  4. Secure the strainer assembly to the filter assembly with the 5 lock tabs (1, 2, 3).
  5. Install the lower housing (2) to the fuel pump filter and upper support assemblies (1).
  6. Secure the lower and upper assemblies by engaging the 2 lock tabs (1).
  7. With the upper support guide posts correctly aligned with lower housing, gently compress the spring (1) and install a new E-clip (2).
  8. Connect the jet tube (2) to the lower housing fuel inlet port (1) and secure with the lock tab.
  9. Connect the fuel pump and fuel level sensor (1) electrical connectors.
  10. Install the fuel sender assembly into the fuel tank. Refer to «Fuel Sender Assembly Replacement»(ref-200095-S34480041992005102000000) .
  1. Remove the four fasteners from the engine cover (1).
  2. Remove the engine cover (1) from the engine.
  3. Relieve the fuel pressure. Refer to «Fuel Pressure Relief Procedure»(ref-200095-S29986787282005102000000) .
  4. Remove the quick connect coupling cover.
  5. Disconnect the coupling for the fuel feed hose from the fuel feed pipe of the fuel rail using the J 43178 . Use a shop towel in order to catch any remaining fuel that may leak. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-200095-S25812448662005102000000) .
  6. Disconnect the PCV hose (1) from the PCV valve.
  7. Disconnect the PCV breather hose (2).
  8. Disconnect the EVAP hose (3).
  9. Swing the two PCV hoses and the EVAP hose away from the cylinder head
  10. Remove the bolt to the ignition coil wire harness bracket.
  11. Disconnect the electrical connectors to the four fuel injectors.
  12. Remove the fastener (1) from the fuel supply pipe bracket.
  13. Remove the two fasteners (4) from the fuel rail (3).
  14. Remove the fuel rail (3) and the spacers (2) from the engine.
  15. Remove the fuel injectors (1) with the O-rings (3) and with the grommets (2) from the fuel rail or cylinder head.
  1. Install new O-rings (3) and new grommets (2) on the fuel injectors (1).
  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.
  4. Install the fuel rail (3) and the spacers (2) onto the engine.
  5. Secure the fuel rail to the engine with the 2 fasteners (4). Tighten: Tighten the fasteners to 29 N.m (21 lb ft).
  6. Install the fastener (1) to the fuel supply pipe bracket. Tighten: Tighten the fastener to 9 N.m (80 lb in).
  7. Connect the electrical connectors to the four fuel injectors.
  8. Install the bolt to the ignition coil wire harness bracket. Tighten: Tighten the fastener to 10 N.m (89 lb in).
  9. Connect the EVAP hose (3).
  10. Connect the PCV breather hose (2).
  11. Connect the PCV hose (1) to the PCV valve.
  12. Connect the quick-connect fitting (1) for the fuel feed hose to the fuel feed pipe (2) of the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-200095-S25812448662005102000000) .
  13. Install the quick connect coupling cover.
  14. Connect the negative battery cable. Tighten: Tighten the retainer for the negative battery cable terminal to 15 N.m (11 lb ft).
  15. Turn ON the ignition in order to pressurize the fuel system.
  16. Turn OFF the ignition.
  17. Inspect for fuel leaks.
  18. Repair any fuel leaks as necessary.
  19. Install the engine cover (1) to the engine.
  20. Secure the engine cover (1) with the four fasteners. Tighten: Tighten the fasteners to 7 N.m (62 lb in).
  1. Disconnect the electrical connector (1) from the evaporative emission (EVAP) canister purge valve (2).
  2. Disconnect the 2 vacuum hoses (4) from the EVAP canister purge valve (2).
  3. Remove the EVAP canister purge valve from the air inlet duct hose.
  4. Inspect the EVAP canister purge valve, and the EVAP purge system for carbon particle contamination, before replacing the EVAP canister purge valve.
  1. Insert the locator pin (3) of the purge valve into the mounting hole on the air inlet duct.
  2. Connect the 2 vacuum hoses (4) to the EVAP canister purge valve (2).
  3. Connect the electrical connector (1) to the EVAP canister purge valve (2).
  1. Remove the evaporative emission (EVAP) canister. Refer to «Evaporative Emission (EVAP) Canister Replacement»(ref-200095-S13047420872005102000000) .
  2. Pinch both sides of the hose connector and disconnect the EVAP filter line from the inlet port (4) of the EVAP vacuum leak pump (2).
  3. Disconnect the vacuum hose from the vacuum leak pump.
  4. Remove the 3 bolts and the EVAP vacuum leak pump (2) from the canister (3).
  1. Install the EVAP vacuum leak pump (2) to the EVAP canister (3) and secure with 3 bolts.
  2. Tighten the pump bolts. Tighten: Tighten the bolts to 8 N.m (71 lb in).
  3. Connect the vacuum hose to the small port of the EVAP leak pump.
  4. Connect the EVAP filter line to the inlet port (4) of the vacuum leak pump (2)
  5. Install the EVAP canister to the vehicle. Refer to «Evaporative Emission (EVAP) Canister Replacement»(ref-200095-S13047420872005102000000) .
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200076-S37188174922005102000000) in General Information.
  2. Unlock the quick connect fitting of the on-board refueling vapor recovery (ORVR) vent line by sliding the lock clasp (1) to unlock position.
  3. Disconnect the ORVR vent line (3) from the evaporative emission (EVAP) canister port (2).
  4. Disconnect the EVAP canister air inlet line (1) from the vent pipe (2) by pinching both sides of the hose connector.
  5. Disconnect the EVAP purge hose (1) from the EVAP canister (3).
  6. Disconnect the electrical connector (4) from the EVAP canister vacuum pump assembly.
  7. Remove the 3 bolts and the EVAP canister (3) from the vehicle.
  8. Inspect the EVAP purge system for carbon particle contamination before replacing the EVAP canister.
  1. Install the EVAP canister (3) to the vehicle underbody and secure with 3 bolts.
  2. Tighten the EVAP canister bracket support bolts. Tighten: Tighten the bolts to 19 N.m (14 lb ft).
  3. Connect the EVAP purge hose (1) to the EVAP canister (3).
  4. Connect the electrical connector (4) to the EVAP canister vacuum pump.
  5. Connect the ORVR vent line (2) to the EVAP canister (3).
  6. Slide the locking clasp of the quick connect fitting into the lock position on the ORVR vent line
  7. Connect the EVAP canister air inlet line (1) to the vent pipe (2).
  8. Lower the vehicle.
  1. Disconnect the evaporative emission (EVAP) canister air inlet line (1) from the vent pipe (2) by pinching both sides of the hose connector.
  2. Disconnect the air filter line from the EVAP canister.
  3. Remove the air filter lines from the 2 front canister clips.
  4. Remove the 3 EVAP canister bracket bolts.
  5. Remove the canister bracket (2) and the air filter (3) from the vehicle.
  6. If necessary, remove the air filter (3) from the bracket (2).
  1. If necessary, connect the air filter (3) to the canister bracket (2).
  2. Install the bracket and filter to the EVAP canister (1).
  3. Secure the bracket (2) to the canister (1) with 2 bolts. NOTE: Refer to «FASTENER NOTICE»(ref-200052-S38758010592005102000000) in Cautions and Notices. Install the EVAP canister bracket bolts. Tighten: Tighten the bolts to 8 N.m (71 lb in).
  4. Secure the bracket to the vehicle chassis with the one bolt. Install the bracket bolt. Tighten: Tighten the bolt to 19 N.m (14 lb ft).
  5. Install the air filter lines into the correct canister clips.
  6. Connect the one air filter line to the canister.
  7. Connect the other air filter line to the chassis vent pipe (4).
  1. Remove the four fasteners from the engine cover (1).
  2. Remove the engine cover (1) from the engine.
  3. Disconnect the 4 electrical connectors from the ignition coils (3).
  4. Remove the fasteners (4) from the ignition coils.
  5. Remove the fasteners (2) from the electrical harness (1).
  6. Remove the electrical harness package (1).
  7. Remove the ignition coils (3) from the cylinder head.
  1. Install the ignition coils (3) to the engine.
  2. Secure the ignition coils with the fasteners (4). Tighten: Tighten the ignition coil fasteners to 9 N.m (80 lb in).
  3. Install the electrical harness (2) and secure with the 2 fasteners (1). Tighten: Tighten the fasteners to 8.8 N.m (78 lb in).
  4. Connect the electrical connectors to the ignition coils (3).
  5. Install the engine cover (1) to the engine.
  6. Secure the engine cover (1) with the four fasteners. Tighten: Tighten the fasteners to 7 N.m (62 lb in).
  1. Remove the four fasteners from the engine cover (1).
  2. Remove the engine cover (1) from the engine.
  3. Disconnect the electrical connector from each ignition coil.
  4. Remove the bolt (1) securing each ignition coil from the cylinder head cover.
  5. Remove each ignition coil (2) from the cylinder head cover.
  6. Remove the spark plugs from the cylinder head.
  7. Inspect the spark plugs for electrode wear, carbon deposits and insulator damage. Refer to «Spark Plug Inspection»(ref-200095-S33242709942005102000000) .
  1. Replace the spark plugs every 144,000 km (90,000 mi).
  2. Set the spark plug gap. Bend only the side electrode. New Spark Plug Gap: 1.0-1.1 mm (0.040-0.043 in) Maximum Used Spark Plug Gap: 1.3 mm (0.051 in)
  3. Install the spark plugs to the cylinder head. Tighten: Tighten the spark plugs to 18 N.m (13 lb ft).
  4. Install each ignition coil (3) to the cylinder head cover.
  5. Secure the ignition coils using the bolts (4). Tighten: Tighten the bolts to 9 N.m (80 lb in).
  6. Connect each ignition coil electrical connector.
  7. Install the engine cover (1) to the engine.
  8. Secure the engine cover (1) with the four fasteners. Tighten: Tighten the fasteners to 7 N.m (62 lb in).
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200076-S37188174922005102000000) in General Information.
  2. Remove the two bolts (3) that secure the stone shield (1).
  3. Remove the four retainers (2) and the stone shield (1).
  4. Disconnect the CKP sensor electrical connector.
  5. Remove the one hold down bolt (2).
  6. Remove the CKP sensor (1) from the front cover of the engine block.
  1. Install the CKP sensor (1) into the front cover of the engine block.
  2. Install the CKP sensor hold down bolt (2). Tighten: Tighten the hold down bolt to 9 N.m (80 lb in).
  3. Connect the CKP sensor electrical connector.
  4. Install the stone shield (1) with the four retainers (2).
  5. Secure the stone shield (1) with the two bolts (3). Tighten: Tighten the two shield bolts to 10 N.m (89 lb in).
  6. Lower the vehicle.
  1. Remove the four fasteners from the engine cover (1).
  2. Remove the engine cover (1) from the engine.
  3. Disconnect the CMP electrical connector (1).
  4. Remove the two CMP sensor hold-down bolts.
  5. Remove the CMP sensor (2) from the cylinder head.
  1. Install the CMP sensor (2) into the cylinder head.
  2. Install the two CMP sensor hold-down bolts. Tighten: Tighten the hold-down bolts to 9 N.m (80 lb in).
  3. Connect the electrical connector (1) to the CMP sensor.
  4. Install the engine cover (1) to the engine.
  5. Secure the engine cover (1) with the four fasteners. Tighten: Tighten the fasteners to 7 N.m (62 lb in).
  1. Remove the four fasteners from the engine cover (1).
  2. Remove the engine cover (1) from the engine.
  3. Remove the two bolts and the generator support brace from the intake manifold.
  4. Remove the one bolt (5) that secures the lower portion of the breather pipe (3) of the positive crankcase ventilation (PCV) system.
  5. Remove the two nuts (1) securing the PCV breather pipe to the cylinder head.
  6. Disconnect the PCV breather hose (4) from the PCV breather pipe (3).
  7. Remove the PCV breather pipe.
  8. Disconnect the electrical connector (1) from the camshaft position (CMP) actuator solenoid valve (2).
  9. Remove the fastener retaining the CMP actuator solenoid valve (1) to the cylinder head.
  10. Remove the CMP actuator solenoid valve (1) and the O-ring (2) from the cylinder head.
  1. Install a new O-ring (2) and the CMP actuator solenoid valve (1) into the cylinder head.
  2. Secure the CMP actuator solenoid valve with the fastener. Tighten: Tighten the fastener to 9 N.m (80 lb in).
  3. Connect the electrical connector (1) to the solenoid valve (2).
  4. Connect the PCV breather hose (4) to the PCV breather pipe (3).
  5. Install the PCV breather pipe (3), with a new gasket (2), to the cylinder head.
  6. Secure the PCV breather pipe to the cylinder head with the two nuts (1). Tighten: Tighten the fastener to 9 N.m (80 lb in).
  7. Secure the lower portion of the PCV breather pipe (3) to intake manifold with the one bolt (5). Tighten: Tighten the bolts to 24 N.m (18 lb ft).
  8. Install the generator support brace to the intake manifold and secure with two bolts. Tighten: Tighten the bolts to 29 N.m (21 lb ft).
  9. Install the engine cover (1) to the engine.
  10. Secure the engine cover (1) with the four fasteners. Tighten: Tighten the fasteners to 7 N.m (62 lb in).
  1. Remove the four fasteners from the engine cover (1).
  2. Remove the engine cover (1) from the engine.
  3. Remove the two bolts and the generator support brace from the intake manifold.
  4. Remove the one bolt (3) that secures the lower portion of the breather pipe (1) of the positive crankcase ventilation (PCV) system.
  5. Remove the two nuts (4) securing the PCV breather pipe to the cylinder head.
  6. Disconnect the PCV breather hose (2) from the PCV breather pipe (1).
  7. Remove the PCV breather pipe.
  8. Remove the oil filter plug (3) from the cylinder head.
  9. Remove the oil filter (2) from the oil filter plug (1).
  1. Install the oil filter (2) into the oil filter plug (1).
  2. Install the oil filter plug (3) with a new O-ring (2) into the cylinder head.
  3. Tighten the oil filter plug. Tighten: Tighten the plug to 30 N.m (22 lb ft).
  4. Connect the PCV breather hose (2) to the PCV breather pipe (1).
  5. Install the PCV breather pipe (1), with a new gasket (5), to the cylinder head.
  6. Secure the PCV breather pipe to the cylinder head with the two nuts (4). Tighten: Tighten the fastener to 9 N.m (80 lb in).
  7. Secure the lower portion of the PCV breather pipe (1) to intake manifold with the one bolt (3). Tighten: Tighten the bolts to 24 N.m (18 lb ft).
  8. Install the generator support brace to the intake manifold and secure with two bolts. Tighten: Tighten the bolts to 29 N.m (21 lb ft).
  9. Install the engine cover (1) to the engine.
  10. Secure the engine cover (1) with the four fasteners. Tighten: Tighten the fasteners to 7 N.m (62 lb in).
  1. Remove the four fasteners from the engine cover (1).
  2. Remove the engine cover (1) from the engine.
  3. Disconnect the PCV hose (1) from the PCV valve.
  4. Disconnect the PCV breather hose (2).
  5. Disconnect the EVAP hose (3).
  6. Swing the two PCV hoses and the EVAP hose away from the cylinder head.
  7. Disconnect the electrical connector from the rocker arm oil control solenoid valve.
  8. Remove the fastener retaining the rocker arm oil control solenoid valve to the cylinder head.
  9. Remove the rocker arm oil control solenoid valve (1) and the O-ring (2) from the cylinder head.
  1. Install a new O-ring (2) and the rocker arm oil control solenoid valve (1) into the cylinder head.
  2. Secure the rocker arm oil control solenoid valve with the one fastener. Tighten: Tighten the fastener to 9 N.m (80 lb in).
  3. Connect the electrical connector to the solenoid valve.
  4. Connect the PCV hose (1) and the PCV breather hose (2) to the engine.
  5. Connect the EVAP hoses.
  6. Install the engine cover (1) to the engine.
  7. Secure the engine cover (1) with the four fasteners. Tighten: Tighten the fasteners to 7 N.m (62 lb in).
  1. Remove the four fasteners from the engine cover (1).
  2. Remove the engine cover (1) from the engine.
  3. Disconnect the PCV hose (1) from the PCV valve.
  4. Disconnect the PCV breather hose (2).
  5. Disconnect the EVAP hose (3).
  6. Swing the two PCV hoses and the EVAP hose away from the cylinder head.
  7. Disconnect the electrical connector from the rocker arm oil pressure switch.
  8. Disconnect the electrical connector from the rocker arm oil control solenoid (1).
  9. Remove the 3 bolts (4) from the rocker arm oil control solenoid housing (2).
  10. Remove the 2 nuts (3) and the rocker arm oil control solenoid housing (2) and gasket from the cylinder head.
  11. Remove the oil filter (1) from the oil passage in the cylinder head.
  1. Install the oil filter (1) of the rocker arm oil control solenoid valve into the oil supply passage of the cylinder head.
  2. Install the rocker arm oil control solenoid housing (2) with gasket onto the cylinder head.
  3. Secure the housing to the cylinder head with the two nuts (3) and the three bolts (4). Tighten: Tighten the fasteners to 9 N.m (80 lb in).
  4. Connect the electrical connector to the rocker arm oil control solenoid (1).
  5. Connect the electrical connector to the rocker arm oil pressure switch.
  6. Connect the PCV hose (1) and the PCV breather hose (2) to the engine.
  7. Connect the EVAP hoses.
  8. Install the engine cover (1) to the engine.
  9. Secure the engine cover (1) with the four fasteners. Tighten: Tighten the fasteners to 7 N.m (62 lb in).
  1. Remove the four fasteners from the engine cover (1).
  2. Remove the engine cover (1) from the engine.
  3. Disconnect the PCV hose (1) from the PCV valve.
  4. Disconnect the PCV breather hose (2).
  5. Disconnect the EVAP hose (3).
  6. Swing the two PCV hoses and the EVAP hose away from the cylinder head.
  7. Disconnect the electrical connector from the rocker arm oil pressure switch.
  8. Remove the rocker arm oil pressure switch (2) from the rocker arm oil control solenoid housing (1).
  1. Install the rocker arm oil pressure switch (2) into the rocker arm oil control solenoid housing (1). Tighten: Tighten the switch to 13 N.m (9.5 lb ft).
  2. Connect the electrical connector to the rocker arm oil pressure switch.
  3. Connect the PCV hose (1) and the PCV breather hose (2) to the engine.
  4. Connect the EVAP hoses.
  5. Install the engine cover (1) to the engine.
  6. Secure the engine cover (1) with the four fasteners. Tighten: Tighten the fasteners to 7 N.m (62 lb in).
  1. Remove the starter motor. Refer to «Starter Motor Replacement»(ref-200056-S27769283752005102000000) in Engine Electrical.
  2. Disconnect the knock sensor (KS) electrical connector.
  3. Remove the nut (1) securing the KS (2) to the engine block.
  4. Remove the KS (2) from the engine block.
  1. Install the KS (2) onto the threaded stud in the engine block.
  2. Install the KS nut (1) to the threaded stud.
  3. Align the KS (1) on the engine block as illustrated. The KS electrical connector cavity must point down, in a 15-30 degree arc from perpendicular to the earth.
  4. Tighten the KS nut while maintaining the correct sensor alignment. Tighten: Tighten the nut to 20 N.m (16 lb ft).
  5. Connect the KS electrical connector.
  6. Install the starter motor. Refer to «Starter Motor Replacement»(ref-200056-S27769283752005102000000) in Engine Electrical.
  1. Disconnect the electrical connector to the auxiliary intake air control solenoid (3).
  2. Disconnect the 2 vacuum lines (2) to the auxiliary intake air control solenoid (3).
  3. Remove the two fasteners (4) and the auxiliary intake air control solenoid (3) from the air cleaner housing.
  1. Install the auxiliary intake air control solenoid (3) to the air cleaner housing with the two fasteners (4). Tighten: Tighten the fasteners to 3.7 N.m (33 lb in).
  2. Connect the 2 vacuum hoses (2) to the auxiliary intake air control solenoid (3).
  3. Connect the electrical connector.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200076-S37188174922005102000000) in General Information.
  2. The secondary air injection (AIR) pump is located above the inner wheel house and stone shield panel.
  3. Remove the 2 bolts (2) that secure the stone shield (1).
  4. Remove the single retainer (3) and the stone shield (1).
  5. Swing the stone shield (1) down in order to gain access to the AIR pump assembly.
  6. Disconnect the AIR pump electrical connector (5).
  7. Disconnect the AIR pump relay electrical connector (4).
  8. Disconnect the electrical ground strap (3).
  9. Disconnect the AIR pump discharge hose (6).
  10. Remove the three AIR pump bracket fasteners (1, 2, 7).
  11. Remove the AIR pump assembly from the vehicle.
  1. Install the AIR pump assembly to the vehicle and secure with 3 fasteners (1, 2, 7). Tighten: Tighten the 3 fasteners to 7 N.m (62 lb in).
  2. Connect the AIR pump discharge hose (6).
  3. Connect the AIR pump relay electrical connector (4).
  4. Connect the AIR pump electrical connector (5).
  5. Connect the electrical ground strap (3). Tighten: Tighten the ground strap fastener to 7 N.m (62 lb in).
  6. Swing the stone shield (1) up and secure with the retaining pin.
  7. Install the 2 bolts that secure the stone shield (1). Tighten: Tighten the 2 shield bolts to 10 N.m (89 lb in).
  8. Lower the vehicle.
  1. Disconnect the electrical connector from the secondary air injection (AIR) solenoid valve.
  2. Disconnect the 2 vacuum hoses (3) from the AIR solenoid valve (3).
  3. Remove the fastener (1) from the AIR solenoid valve (2).
  4. Remove the AIR solenoid valve (2) from the intake manifold.
  1. Install the AIR solenoid valve (2) to the intake manifold with the one fastener (1).
  2. Tighten the AIR solenoid valve fastener (1). Tighten: Tighten the fastener to 8.8 N.m (77 lb in).
  3. Connect the vacuum hoses (3) to the secondary AIR solenoid valve (2).
  4. Connect the electrical connector to the AIR solenoid valve.
  1. Disconnect the electrical connector (1) from the secondary air injection (AIR) pressure sensor (2).
  2. Remove the 2 fasteners of the AIR pressure sensor (2).
  3. Remove the AIR pressure sensor (2) from the shut-off valve (3).
  1. Install the AIR pressure sensor (2) to the shut-off valve (3).
  2. Secure the AIR pressure sensor with 2 fasteners. Tighten: Tighten the 2 fasteners to 5 N.m (44 lb in).
  3. Connect the electrical connector (1) to the AIR pressure sensor (2).
  1. Remove the secondary air injection (AIR) pressure sensor. Refer to «Secondary AIR Injection Pressure Sensor Replacement»(ref-200095-S30794135052005102000000) .
  2. Disconnect the air inlet hose (2) from the AIR shut-off valve (3).
  3. Disconnect the air outlet hose (4) from the AIR shut-off valve.
  4. Remove the 2 fasteners (1) from the AIR shut-off valve bracket.
  5. Remove the AIR shut-off valve and bracket from the engine.
  6. Remove the 2 bolts securing the AIR shut-off valve to the bracket and pipe assembly.
  7. Remove the AIR shut-off valve.
  1. Install the AIR shut-off valve (3) and gasket (4) to the bracket and pipe assembly (5).
  2. Secure the 3 parts with the 2 bolts. Tighten: Tighten the 2 fasteners to 8 N.m (71 lb in).
  3. Install the AIR shut-off valve and bracket to the engine.
  4. Secure the AIR shut-off valve (3) with the 2 bolts (1). Tighten: Tighten the 2 fasteners to 21 N.m (16 lb ft).
  5. Connect the air inlet hose (2) to the AIR shut-off valve (3).
  6. Connect the air outlet hose (4) to the AIR shut-off valve.
  7. Install the AIR pressure sensor. Refer to «Secondary AIR Injection Pressure Sensor Replacement»(ref-200095-S30794135052005102000000) .
  1. Loosen the positive crankcase ventilation (PCV) valve hose clamp (2).
  2. Remove the PCV valve hose (3) from the PCV valve.
  3. Remove the PCV valve (1) from the cylinder head.
  1. Install the PCV valve (1) into the cylinder head. Tighten: Tighten the PCV valve to 27 N.m (13 lb ft).
  2. Connect the PCV valve hose (3) to the PCV valve (1).
  3. Secure the PCV valve hose with one clamp (2).
  1. Disconnect the mass air flow (MAF) sensor.
  2. Remove the accelerator cable from the cable guide wire.
  3. Remove the auxiliary intake air control solenoid from the air cleaner cover. Refer to «Auxiliary Intake Air Control Solenoid Replacement»(ref-200095-S21576324592005102000000) .
  4. Remove the evaporative emission (EVAP) canister purge valve from the air cleaner cover. Refer to «Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement»(ref-200095-S05667229812005102000000) .
  5. Disconnect the vacuum hoses from the auxiliary intake air control system.
  6. Release the 2 retaining clips (3).
  7. Loosen the air inlet duct clamp (1).
  8. Disconnect the air inlet duct at the throttle body (1).
  9. Remove the air cleaner upper assembly (2).
  10. Remove the air cleaner element (3).
  11. Remove the 3 bolts (5) from the air cleaner lower assembly.
  12. Remove the air cleaner lower assembly (4) from the vehicle.
  1. Install the air cleaner lower assembly (4) to the vehicle.
  2. Secure the air cleaner lower assembly to the vehicle with 3 bolts (5). Tighten: Tighten the 3 bolts to 7 N.m (62 lb in).
  3. Install the air cleaner element (3) into the air cleaner lower assembly (4).
  4. Install the air cleaner upper assembly (2) onto the air cleaner lower assembly (4).
  5. Secure the air cleaner upper assembly (2) with the 2 retaining clips (3).
  6. Connect the air inlet duct to the throttle body (1).
  7. Secure the air inlet duct with the hose clamp.
  8. Connect the vacuum hoses of the auxiliary intake air control system.
  9. Install the auxiliary intake air control solenoid to the air cleaner cover. Refer to «Auxiliary Intake Air Control Solenoid Replacement»(ref-200095-S21576324592005102000000) .
  10. Install the EVAP canister purge valve to the air cleaner cover. Refer to «Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement»(ref-200095-S05667229812005102000000) .
  11. Connect the MAF sensor.
  12. Install the accelerator cable into the cable guide wire.
  1. Disconnect the mass air flow (MAF) sensor.
  2. Release the two front retaining clips (3).
  3. Lift the air cleaner cover (1) up and away from the lower assembly (3).
  4. Remove the air cleaner element (2).
  1. Install the air cleaner element (2).
  2. Lower the air cleaner cover (1) onto the lower assembly (3).
  3. Secure the air cleaner cover (2) with the two retaining clips (3).
  4. Connect the MAF sensor.

More articles — Engine Control System - 1.8L (Lnk) - Introduction