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Engine Control System - 1.8L (LV6) - Introduction: Removal & Installation Pontiac Vibe I рестайлинг

Testing & Diagnostics ~10077 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 2 retainers from the PCM close out panel (1) below the instrument panel (I/P) compartment door.
  3. Swing the PCM close out panel (1) down.
  4. Open the I/P compartment.
  5. Push in on both sides of the I/P compartment in order to release the safety catches.
  6. Remove the I/P compartment door assembly from the I/P.
  7. Remove the 2 PCM bracket fasteners.
  8. Pull the PCM (2) with brackets (3) toward you and swing both down away from under the I/P.
  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 2 PCM brackets (3) to the PCM (2).
  2. Secure the 2 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 4 PCM electrical connectors (1).
  4. Swing the PCM (2) with bracket (3) up in position under the I/P.
  5. Secure the PCM to the I/P with the 2 fasteners. Tighten: Tighten the two fasteners to 9 N.m (80 lb in).
  6. Install the I/P compartment door into the I/P.
  7. Push in on both sides of the I/P 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).
  1. Remove the 2 fasteners.
  2. Remove the 2 plastic retainers.
  3. Remove the engine cover (1) from the engine.
  4. Disconnect the HO2S 1 electrical connector.
  5. Remove the HO2S 1 (1) from the exhaust manifold (2).
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 (1) into the exhaust manifold.
  2. Tighten the HO2S 1. Tighten: Tighten the HO2S 1 to 44 N.m (32 lb ft).
  3. Connect the electrical connector (2) of the HO2S 1.
  4. Install the engine cover (1).
  5. Secure the engine cover (1) with the 2 fasteners. Tighten: Tighten the two fasteners to 7 N.m (62 lb in).
  6. Install the 2 plastic retainers.
  1. Remove the 2 fasteners.
  2. Remove the 2 plastic retainers.
  3. Remove the engine cover (1) from the engine.
  4. Disconnect the HO2S 1 electrical connector.
  5. Remove the HO2S 1 (1) from the exhaust manifold (2).
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 (1) into the exhaust manifold (2).
  2. Tighten the HO2S 1. Tighten: Tighten the HO2S 1 to 44 N.m (32 lb ft).
  3. Connect the electrical connector of the HO2S 1.
  4. Install the engine cover (1).
  5. Secure the engine cover (1) with the 2 fasteners. Tighten: Tighten the two fasteners to 7 N.m (62 lb in).
  6. Install the 2 plastic retainers.
  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 2 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 2 wiring pigtail and body plug from the floor pan.
  6. Remove the HO2S 2 (1) 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 (1) 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 into the floor pan.
  4. Lower the vehicle.
  5. Connect the HO2S 2 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).
  1. Remove the right side front seat assembly. Refer to «Seat Replacement - Front Bucket»(ref-200065-S27378337552005102000000) in Seats.
  2. Remove the right door sill plate and carpet trim.
  3. Pull back the carpet under the seat and sill plate area.
  4. Disconnect the HO2S 2 electrical connector (1).
  5. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200076-S37188174922005102000000) in General Information.
  6. Remove the HO2S 2 wiring pigtail and body plug (2) from the floor pan.
  7. Remove the HO2S 2 (1) 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 (1) 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 (2) into the floor pan.
  4. Lower the vehicle.
  5. Connect the HO2S 2 wiring pigtail (2) to the HO2S harness connector (1).
  6. Relocate the carpet under the seat and the left sill plate area.
  7. Install the door sill plate and carpet trim.
  8. Install the front seat assembly. Refer to «Seat Replacement - Front Bucket»(ref-200065-S27378337552005102000000) in Seats.

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 2 fasteners (3) from the throttle position (TP) sensor (2).
  2. 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).
  1. Disconnect the electrical connector (2) from the APP sensor (1).
  2. Remove the 2 fasteners (3) and the APP sensor and pedal assembly (1).
  1. Install the APP sensor and pedal assembly (1) to the vehicle.
  2. Secure the accelerator pedal assembly to the vehicle with 2 fasteners (3). NOTE: Refer to Fastener Notice in Cautions and Notices. Tighten: Tighten the 2 fasteners to 5 N.m (44 lb in).
  3. Connect the electrical connector (2) to the APP sensor (1).
  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 2 nuts and the 2 retainers from the engine cover (1).
  2. Remove the engine cover (1) from the engine.
  3. Loosen the clamp and remove the air inlet duct (2) from the throttle body assembly (1).
  4. Disconnect the electrical connector (2) of the throttle actuator control (TAC) module.
  5. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-200120-S08195956722005102000000) in Engine Cooling.
  6. Disconnect the 2 coolant hoses (3) from the throttle body (1).
  7. Remove the upper 2 fasteners (2) and the lower 2 fasteners (4) from the throttle body (3).
  8. Remove the throttle body (3) and the gasket (1) from the intake manifold.
  9. Clean any remaining throttle body gasket from the intake manifold.
  1. Install a new throttle body gasket (1) onto the intake manifold.
  2. Install the throttle body (3) onto the intake manifold.
  3. Secure the throttle body to the manifold with 4 fasteners (2, 4). Install the 4 throttle body fasteners. Tighten: Tighten the fasteners to 9 N.m (80 lb in).
  4. Connect the 2 coolant hoses (3) to the throttle body (1).
  5. Connect the TAC module electrical connector (2).
  6. Install the air inlet duct (2) to the throttle body (1).
  7. Refill the cooling system. Refer to «Draining and Filling Cooling System»(ref-200120-S08195956722005102000000) in Engine Cooling.
  8. Install the engine cover (1) to the engine.
  9. Secure the engine cover (1) with the 2 nuts. Tighten: Tighten the fasteners to 7 N.m (62 lb in).
  10. Install the 2 retainers to the engine cover.
  1. Remove the 2 nuts and the 2 retainers from the engine cover (1).
  2. Remove the engine cover (1) from the engine.
  3. Remove the air inlet duct (4) from the throttle body assembly (6).
  4. Remove the positive crankcase ventilation (PCV) breather hose (1).
  5. Remove the throttle position (TP) sensor connector (3).
  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 (2) from the throttle body.
  10. Remove the 2 bolts and the accelerator control cable bracket (5).
  11. Remove the 2 fasteners and the throttle body bracket (4).
  12. Remove the 3 throttle body fasteners (3).
  13. Remove the 2 fasteners and the manifold support bracket (3).
  14. Remove the throttle body (2) and the gasket (6) from the intake manifold.
  15. Clean any remaining throttle body gasket from the intake manifold.
  1. Install a new throttle body gasket (1) onto the intake manifold (2).
  2. Install the throttle body (2) onto the intake manifold with the 3 fasteners (3).
  3. Install the throttle body bracket (4) and the 2 bolts to the throttle body.
  4. Install the 5 throttle body fasteners. Tighten: Tighten the fasteners to 30 N.m (22 lb ft).
  5. Install the manifold support bracket (1) to the throttle body with 2 bolts. Install the 2 fasteners. Tighten: Tighten the fasteners to 30 N.m (22 lb ft).
  6. Install the accelerator control cable bracket (5) to the throttle body with 2 bolts. Install the 2 fasteners. Tighten: Tighten the fasteners to 13 N.m (10 lb ft).
  7. Connect the 2 coolant hoses (2) to the throttle body (6).
  8. Connect the PCV breather hose (1) to the throttle body (6).
  9. Connect the IAC valve electrical connector (5).
  10. Connect the TP sensor electrical connector (3).
  11. Install the air inlet duct (4).
  12. Refill the cooling system. Refer to «Draining and Filling Cooling System»(ref-200120-S08195956722005102000000) in Engine Cooling.
  13. Install the engine cover (1) to the engine.
  14. Secure the engine cover (1) with the 2 nuts. Tighten: Tighten the fasteners to 7 N.m (62 lb in).
  15. Install the 2 retainers to the engine cover.
  1. Relieve the fuel pressure. Refer to «Fuel Pressure Relief Procedure»(ref-200095-S29986787282005102000000) .
  2. Remove the 2 fasteners.
  3. Remove the 2 plastic retainers.
  4. Remove the engine cover (1) from the engine.
  5. Remove the quick connect coupling cover of the fuel feed hose.
  6. 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-200094-S32421134232005102000000) .
  7. Install the J 42982 between the fuel feed pipe of the fuel rail and of the fuel feed hose.
  8. Install the J 34730-1A to the J 42982 , and tighten securely.
  9. Connect the negative battery cable. Tighten: Tighten the retainer for the negative battery cable terminal to 15 N.m (11 lb ft).
  10. Turn ON the ignition in order to pressurize the fuel system.
  11. Turn OFF the ignition.
  12. 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-200094-S32421134232005102000000) .
  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).
  12. Secure the engine cover (1) with the 2 fasteners. Tighten: Tighten the two fasteners to 7 N.m (62 lb in).
  13. Install the 2 plastic retainers.
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 (LV6 Engine)»(ref-200084-S23866561112005102000000) or «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 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 (LV6 Engine)»(ref-200084-S23866561112005102000000) or «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 quick connect clasp (1) into the lock position on the ORVR vent line (2).
  16. Connect the fuel supply line (1) to the fuel sender assembly.
  17. Secure the fuel supply line (2) to the sender assembly with the retaining clip (1).
  18. Connect the fuel sender electrical connector (2) to the fuel sender assembly.
  19. Add fuel to the fuel tank.
  20. Connect the negative battery cable. Tighten: Tighten the retainer for the negative battery cable terminal to 15 N.m (11 lb ft).
  21. Pressurize the fuel system and check for leaks.
  22. Install the access panel (1) to the rear seat floor panel (3).
  23. Secure the access panel to the body with 4 bolts. Tighten: Tighten the 4 bolts to 6 N.m (53 lb in).
  24. Relocate the carpet under the ride side seat area and the right sill plate area.
  25. Install the sill plate to the right side door opening.
  26. 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).
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 propeller shaft from the vehicle. Refer to «Propeller Shaft Replacement - Two Piece»(ref-200085-S26257744062005102000000) in Propeller Shaft.
  4. Remove the catalytic converter and intermediate pipe assembly from the vehicle. Refer to «Catalytic Converter Replacement (LV6 Engine)»(ref-200084-S23866561112005102000000) or «Catalytic Converter Replacement (LNK Engine)»(ref-200084-S26932355542005102000000) in Engine Exhaust.
  5. Remove the 4 rivets (2) securing the rear exhaust heat shield (3) to the vehicle.
  6. Remove the rear exhaust heat shield (3) from the fuel tank (1).
  7. Remove the 3 bolts (1) securing the parking brake cable (2) on the left side of the vehicle.
  8. Remove the 3 bolts (1) securing the parking brake cable (3) on the evaporative emission (EVAP) canister (2) side of the vehicle.
  9. Disconnect the EVAP drain hose (2) from the EVAP canister (1).
  10. Disconnect the EVAP purge and vent lines (3) from the EVAP canister (2).
  11. Remove the EVAP lines (3) from the body clip (1) and swing the lines away from the fuel tank.
  12. Remove the EVAP canister (2). Refer to «Evaporative Emission (EVAP) Canister Replacement (FWD)»(ref-200094-S40352068482005102000000) or «Evaporative Emission (EVAP) Canister Replacement (AWD)»(ref-200094-S27752223162005102000000) .
  13. Disconnect the fuel supply line. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200094-S27544717142005102000000) .
  14. Loosen the fuel filler hose clamp (1).
  15. Disconnect the fuel filler hose (2) from the fuel tank.
  16. Disconnect the 2 filler pipe vent lines (2) from the fuel tank.
  17. Support the fuel tank with a transmission jack or other suitable fixture.
  18. Remove the four bolts (3) and the two fuel tank straps (1) from the vehicle.
  19. Remove the fuel tank from the vehicle.
  20. If replacing the fuel tank, remove all lines, hoses, and the FLVV, and install on the replacement fuel tank. Refer to «Fill Limiter Vent Valve Replacement (AWD)»(ref-200094-S28083223602005102000000) .
  1. Install the fuel tank to the vehicle.
  2. Install the 2 fuel tank straps (1) to the vehicle with the four bolts (3). Tighten: Tighten the bolts to 39 N.m (29 lb ft).
  3. Connect the 2 filler pipe vent lines (2) to the fuel tank.
  4. Connect the fuel filler hose (2) to the fuel tank.
  5. Secure the fuel filler hose (2) to the fuel tank with the hose clamp (1).
  6. Connect the fuel supply line. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200094-S27544717142005102000000) .
  7. Install the EVAP canister to the vehicle. Refer to «Evaporative Emission (EVAP) Canister Replacement (FWD)»(ref-200094-S40352068482005102000000) or «Evaporative Emission (EVAP) Canister Replacement (AWD)»(ref-200094-S27752223162005102000000) .
  8. Secure the EVAP purge and vent lines (3) to the chassis with the body clip (1).
  9. Connect the EVAP lines (3) to the EVAP canister (2).
  10. Connect the EVAP drain hose (2) to the EVAP canister (1).
  11. Secure the parking brake cable (3) on the EVAP canister (2) side of the vehicle with 3 bolts (1). Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
  12. Secure the parking brake cable (2) on the left side of the vehicle with 3 bolts (1). Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
  13. Install the rear exhaust heat shield (3) to the fuel tank (1).
  14. Secure the rear exhaust heat shield (3) with four rivets (2).
  15. Install the propeller shaft. Refer to «Propeller Shaft Replacement - Two Piece»(ref-200085-S26257744062005102000000) in Propeller Shaft.
  16. Install the catalytic converter and intermediate exhaust pipe assembly to the vehicle. Refer to «Catalytic Converter Replacement (LV6 Engine)»(ref-200084-S23866561112005102000000) or «Catalytic Converter Replacement (LNK Engine)»(ref-200084-S26932355542005102000000) in Engine Exhaust.
  17. Lower the vehicle.
  18. Install the fuel supply line (1) to the fuel sender fitting.
  19. Secure the fuel supply line (1) with the retaining clip (2).
  20. Connect the fuel sender electrical connector (2) to the fuel sender assembly.
  21. Connect the fuel tank pressure (FTP) sensor electrical connector (1) to the fuel sender assembly.
  22. Add fuel to the fuel tank.
  23. Connect the negative battery cable. Tighten: Tighten the retainer for the negative battery cable terminal to 15 N.m (11 lb ft).
  24. Pressurize the fuel system and check for leaks.
  25. Inspect the butyl caulk seal for the fuel sender access panel. Replace any missing butyl caulk as necessary.
  26. Install the access panel to the rear seat floor.
  27. Install the sill plate to the left side door opening.
  28. Install the rear seat bottom cushion. Refer to «Seat Cushion Replacement - Rear»(ref-200065-S13765604562005102000000) in Seats.
  1. Remove The Fuel Sender Assembly (2) From The Fuel Tank. Refer To «fuel Sender Assembly Replacement (FWD)»(ref-200094-S00528292382005102000000) Or «fuel Sender Assembly Replacement (AWD)»(ref-200094-S34295836252005102000000) .
  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. 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) 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 (FWD)»(ref-200094-S25088299822005102000000) or «Fuel Pressure Regulator Replacement (AWD)»(ref-200094-S11875652042005102000000) .
  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 filter assembly (2).
  4. Connect the fuel pump electrical connector (1).
  5. 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).
  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 2 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 (FWD)»(ref-200094-S00528292382005102000000) or «Fuel Sender Assembly Replacement (AWD)»(ref-200094-S34295836252005102000000) .
  1. Remove the fuel sender assembly. Refer to «Fuel Sender Assembly Replacement (FWD)»(ref-200094-S00528292382005102000000) or «Fuel Sender Assembly Replacement (AWD)»(ref-200094-S34295836252005102000000) .
  2. Remove the bottom cap (2) and the lower cushion (3) from the fuel sender assembly.
  3. Remove the fuel pressure regulator (1).
  4. Disconnect the fuel level sensor electrical connector.
  5. Remove the fuel level sensor (1).
  6. Remove the fuel sender top cap (1) from the fuel filter assembly.
  7. Disconnect the fuel pump electrical connector.
  8. Remove the fuel pump (1) from the fuel filter assembly (2).
  9. Remove the retaining ring for the fuel strainer from the fuel pump.
  1. Install the fuel pump strainer (7) to the fuel pump (11). Use a new locking ring (10).
  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).
  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 the electrical connector (4) to the fuel pump. Ensure that connections are secure at the fuel pump and the top cap (2) of the sender assembly.
  7. Install the fuel sender assembly top cap (2) to the fuel filter assembly (13). The fuel sender assembly end caps snap into place.
  8. Install the fuel level sensor (3) to the fuel sender assembly.
  9. Connect the fuel level sensor electrical connector.
  10. Position lower cushion (8) on bottom of fuel pump and install lower cap (9) to fuel filter assembly.
  1. Remove the two fasteners and swing the rear seat bottom cushion up and out of the way. Refer to «Seat Cushion Replacement - Rear»(ref-200065-S13765604562005102000000) in Seats.
  2. Remove the 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 electrical connector (2) from the fuel sender assembly.
  6. Disconnect the electrical connector of the fuel tank pressure (FTP) sensor (1) from the fuel sender assembly.
  7. Remove the retaining clip (2) from the FTP sensor.
  8. Remove the FTP sensor (1) from the fuel sender assembly.
  1. Install the FTP sensor (1) to the fuel sender assembly.
  2. Install the retaining clip (2) to the FTP sensor.
  3. Connect the fuel sender electrical connector (2).
  4. Connect the FTP sensor electrical connector (1).
  5. Inspect the butyl caulk seal for the fuel sender access panel (1). Replace any missing butyl caulk as necessary.
  6. Install the access panel to the rear seat floor.
  7. Relocate the carpet under the seat and the left sill plate area.
  8. Install the sill plate to the left side door opening.
  9. Install the rear seat bottom cushion.
  10. Secure the seat cushion with the two fasteners. Refer to «Seat Cushion Replacement - Rear»(ref-200065-S13765604562005102000000) in Seats.
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 of 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 on-board refueling vapor recovery (ORVR) vent line (1). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200094-S27544717142005102000000) .
  10. Disconnect the ORVR vent line (2) from the fuel sender assembly (1).
  11. Use the CH-47717 fuel lock ring remover tool (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. Remove the lock ring (1).
  14. 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 fuel tank lock ring tool (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).
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 two fasteners and swing the rear seat bottom cushion up and out of the way. Refer to «Seat Cushion Replacement - Rear»(ref-200065-S13765604562005102000000) in Seats.
  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 electrical connector (2) from the fuel sender assembly.
  7. Disconnect the FTP sensor electrical connector (1) from the fuel sender assembly.
  8. Remove the retaining clip (2) from the fuel line fitting.
  9. Remove the fuel line (1) from the fuel sender assembly.
  10. Remove the 8 bolts (1) retaining the hold down plate (2) for the fuel sender assembly.
  11. Remove the hold down plate (2).
  12. Clean the fuel pipe and the fuel sender assembly to prevent possible fuel contamination during removal.
  13. Remove the fuel sender assembly (3) from the fuel tank.
  14. Inspect and clean O-ring sealing surfaces on the fuel sender assembly.

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 the new fuel sender assembly O-ring (4) on the fuel sender assembly.
  2. Install the fuel sender assembly (3) into the fuel tank.
  3. Install the hold down plate (2) for the fuel sender assembly.
  4. Secure the hold down plate for the fuel sender assembly with the 8 bolts (1). Tighten: Tighten the bolts to 6 N.m (53 lb in).
  5. Install the fuel pipe (1) to the fuel sender fitting.
  6. Secure the fuel pipe (1) with the retaining clip (2).
  7. Connect the fuel sender electrical connector (2) to the fuel sender assembly.
  8. Connect the FTP sensor electrical connector (1) to the fuel sender assembly.
  9. Connect the negative battery cable.
  10. Pressurize the fuel system and check for leaks.
  11. Inspect the butyl caulk seal for the fuel sender access panel. Replace any missing butyl caulk as necessary.
  12. Install the access panel to the rear seat floor.
  13. Relocate the carpet under the seat and the left sill plate area.
  14. Install the sill plate to the left side door opening.
  15. Install the rear seat bottom cushion.
  16. Secure the seat cushion with the two fasteners. Refer to «Seat Cushion Replacement - Rear»(ref-200065-S13765604562005102000000) in Seats.
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (FWD)»(ref-200094-S37372998092005102000000) or «Fuel Tank Replacement (AWD)»(ref-200094-S32766994432005102000000) .
  2. Remove the three bolts (2) and the FLVV cover (1) from the fuel tank.
  3. Disconnect the two EVAP lines from the FLVV.
  4. Remove the three bolts (2) and the FLVV (1) and gasket (3) from the fuel tank.
  1. Install the FLVV (1) and the gasket (2) into the fuel tank.
  2. Secure the FLVV (1) to the fuel tank with the three bolts (2). Tighten: Tighten the bolts to 6 N.m (53 lb in).
  3. Install the FLVV cover (1) onto the FLVV and secure with the three bolts (2). Tighten: Tighten the bolts to 6 N.m (53 lb in).
  4. Install the fuel tank. Refer to «Fuel Tank Replacement (FWD)»(ref-200094-S37372998092005102000000) or «Fuel Tank Replacement (AWD)»(ref-200094-S32766994432005102000000) .
  1. Remove the 2 fasteners.
  2. Remove the 2 plastic retainers.
  3. Remove the engine cover (1) from the engine.
  4. Relieve the fuel pressure. Refer to «Fuel Pressure Relief Procedure»(ref-200095-S29986787282005102000000) .
  5. Remove the quick connect coupling cover.
  6. 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-200094-S32421134232005102000000) .
  7. Disconnect the breather hose from the cylinder head (1).
  8. Disconnect the four electrical connectors (1) from the fuel injectors.
  9. Release the three clamps (2) from the fuel injector wire harness.
  10. Lift the fuel injector wire harness up and away from the fuel rail.
  11. Remove the fastener (2) from the fuel pipe bracket.
  12. Remove the fasteners (1) from the fuel rail (7).
  13. Remove the fuel rail (7) and the spacers (3) from the engine.
  14. Remove the fuel injectors (5) with the O-rings (6) and with the grommets (4).

Installation Procedures

  1. Install new O-rings (6) and new grommets (4) on the fuel injectors (5).
  2. Apply clean engine oil to the O-rings (6) and to the grommets (4).
  3. Install the fuel injectors (5) into the fuel rail.
  4. Install the fuel rail (7) and the spacers (3) onto the engine.
  5. Secure the fuel rail to the engine with the 2 fasteners (1). Tighten: Tighten the fasteners to 19 N.m (13 lb ft).
  6. Install the fastener (2) to the fuel pipe bracket. Tighten: Tighten the fastener to 9 N.m (80 lb in).
  7. Secure the fuel injector wire harness to the engine with the three clamps (2).
  8. Connect the fuel injector electrical connectors (1) to the four fuel injectors.
  9. Connect the PCV breather hose (1) to the cylinder head cover.
  10. 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-200094-S32421134232005102000000) .
  11. Install the quick connect coupling cover.
  12. Connect the negative battery cable. Tighten: Tighten the two battery cable fasteners to 15 N.m (11 lb in).
  13. Turn ON the ignition in order to pressurize the fuel system.
  14. Turn OFF the ignition.
  15. Inspect for fuel leaks.
  16. Repair any fuel leaks as necessary.
  17. Install the engine cover (1).
  18. Secure the engine cover (1) with the 2 fasteners. Tighten: Tighten the two fasteners to 7 N.m (62 lb in).
  19. Install the 2 plastic retainers.
  1. Remove the fuel sender assembly (2) from the fuel tank. Refer to «Fuel Sender Assembly Replacement (FWD)»(ref-200094-S00528292382005102000000) or «Fuel Sender Assembly Replacement (AWD)»(ref-200094-S34295836252005102000000) .
  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) the fuel pump strainer assembly.
  8. Remove the fuel pressure regulator (1) from the fuel filter assembly (2).
  1. Lubricate all O-rings (4, 11) with fuel during assembly. Use the exploded view to aid in assembly.
  2. Install 2 new O-rings (1) onto the fuel pressure regulator.
  3. Install the fuel pressure regulator (1) into the fuel filter assembly (2).
  4. 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).
  5. Secure the strainer assembly to the filter assembly with the 5 lock tabs (1, 2, 3).
  6. Install the lower housing (2) to the fuel pump filter and upper support assemblies (1).
  7. Secure the lower and upper assemblies using the 2 lock tabs (1).
  8. With the upper support guide posts correctly aligned with lower housing, gently compress the spring (1) and install a new E-clip (2).
  9. Connect the jet tube (2) to the lower housing fuel inlet port (1) and secure with the lock tab.
  10. Connect the fuel pump and fuel level sensor (1) electrical connectors.
  11. Install the fuel sender assembly into the fuel tank. Refer to «Fuel Sender Assembly Replacement (FWD)»(ref-200094-S00528292382005102000000) or «Fuel Sender Assembly Replacement (AWD)»(ref-200094-S34295836252005102000000) .
  1. Remove the fuel sender assembly. Refer to «Fuel Sender Assembly Replacement (FWD)»(ref-200094-S00528292382005102000000) or «Fuel Sender Assembly Replacement (AWD)»(ref-200094-S34295836252005102000000) .
  2. Remove the bottom cap (2) and the lower cushion (3) from the fuel sender assembly.
  3. Remove the fuel pressure regulator (1) from the fuel filter assembly (2).
  1. Apply gasoline to a new fuel pressure regulator O-ring (1).
  2. Install the new O-ring (1) onto the fuel pressure regulator (2).
  3. Install the fuel pressure regulator (1) into the fuel filter assembly (2).
  4. Install the fuel pressure regulator (1) into the fuel sender assembly.
  5. 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.
  6. Install the fuel sender assembly to the fuel tank. Refer to «Fuel Sender Assembly Replacement (FWD)»(ref-200094-S00528292382005102000000) or «Fuel Sender Assembly Replacement (AWD)»(ref-200094-S34295836252005102000000)
  1. Remove the 2 fasteners.
  2. Remove the 2 plastic retainers.
  3. Remove the engine cover (1) from the engine.
  4. Relieve the fuel pressure. Refer to «Fuel Pressure Relief Procedure»(ref-200095-S29986787282005102000000) .
  5. Remove the quick connect coupling cover.
  6. 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-200094-S32421134232005102000000) .
  7. Disconnect the breather hose from the cylinder head (1).
  8. Disconnect the four electrical connectors (1) from the fuel injectors.
  9. Release the three clamps (2) from the fuel Injector wire harness.
  10. Lift the fuel Injector wire harness up and away from the fuel rail.
  11. Remove the fastener (2) from the fuel pipe bracket.
  12. Remove the fasteners (1) from the fuel rail (7).
  13. Remove the fuel rail (7) and the spacers (3) from the engine.
  14. Remove the fuel injectors (5) with the O-rings (6) and with the grommets (4).
  1. Install new O-rings (6) and new grommets (4) on the fuel injectors (5).
  2. Apply clean engine oil to the O-rings (6) and to the grommets (4).
  3. Install the fuel injectors (5) into the fuel rail.
  4. Install the fuel rail (7) and the spacers (3) onto the engine.
  5. Secure the fuel rail to the engine with the 2 fasteners (1). Tighten: Tighten the fasteners to 19 N.m (13 lb ft).
  6. Install the fastener (2) to the fuel pipe bracket. Tighten: Tighten the fastener to 9 N.m (80 lb in).
  7. Secure the fuel injector wire harness to the engine with the three clamps (2).
  8. Connect the fuel injector electrical connectors (1) to the four fuel injectors.
  9. Connect the PCV breather hose (1) to the cylinder head cover.
  10. 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-200094-S32421134232005102000000) .
  11. Install the quick connect coupling cover.
  12. Connect the negative battery cable. Tighten: Tighten the two battery cable fasteners to 15 N.m (11 lb in).
  13. Turn ON the ignition in order to pressurize the fuel system.
  14. Turn OFF the ignition.
  15. Inspect for fuel leaks.
  16. Repair any fuel leaks as necessary.
  17. Install the engine cover (1).
  18. Secure the engine cover (1) with the 2 fasteners. Tighten: Tighten the two fasteners to 7 N.m (62 lb in).
  19. Install the 2 plastic retainers.
  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. Disconnect the electrical connector (1) from the evaporative emission (EVAP) canister purge valve (2).
  2. Remove the purge hose (3) from the EVAP canister purge valve (2).
  3. Remove the vacuum hose (4) from the EVAP canister purge valve (2).
  4. Remove the EVAP canister purge valve from the air cleaner housing.
  5. Inspect the EVAP canister purge valve and the EVAP purge system for carbon particle contamination before replacing the EVAP canister purge valve.
  1. Install the EVAP canister purge valve (2) to the air cleaner housing.
  2. Connect the purge hose (3) to the EVAP canister purge valve (2).
  3. Connect the vacuum hose (4) to the EVAP canister purge valve (2).
  4. Connect the electrical connector (1) to the EVAP canister purge valve (2).

Note. The EVAP canister may have released carbon particles which caused this part to fail and may cause damage to other components. Check the EVAP canister for loose carbon before returning the vehicle to service.

  1. Remove the one vent hose (4) from the air cleaner and the evaporative emission (EVAP) canister vent valve (3).
  2. Disconnect the other vent hose (4) from the EVAP canister vent valve (3).
  3. Disconnect the electrical connector (1) from the EVAP canister vent valve (3).
  4. Remove the fastener (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.
  1. Inspect the EVAP canister vent solenoid valve and the EVAP control system for carbon particle contamination before replacing the EVAP canister vent solenoid.
  2. Install the EVAP canister vent valve (3) to the air cleaner housing with the one fastener (2).
  3. Install the EVAP canister vent valve fastener (2). Tighten: Tighten the fastener to 8.8 N.m (77 lb in).
  4. Connect the one vent hose (4) to the EVAP canister vent valve (3) and the air cleaner housing.
  5. Connect the other vent hose (4) to the EVAP canister vent valve (3).
  6. Connect the electrical connector (1) to the vent valve.
  1. Remove the evaporative emission (EVAP) canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (FWD)»(ref-200094-S40352068482005102000000) or «Evaporative Emission (EVAP) Canister Replacement (AWD)»(ref-200094-S27752223162005102000000) .
  2. Disconnect the EVAP filter line from the inlet port (4) of the EVAP vacuum leak pump (2) by pinching both sides of the hose connector fitting.
  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. Install 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 (FWD)»(ref-200094-S40352068482005102000000) or «Evaporative Emission (EVAP) Canister Replacement (AWD)»(ref-200094-S27752223162005102000000) .
  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. Install 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. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200076-S37188174922005102000000) in General Information.
  2. Disconnect the ORVR vent line (1) from the EVAP canister port by pinching both sides of the hose connector (1).
  3. Disconnect the EVAP vapor line (1) from the EVAP canister port by pinching both sides of the hose connector (1).
  4. Disconnect the 3 EVAP hoses (1) from the EVAP canister (3).
  5. Disconnect the electrical connector (4) from the EVAP pressure switching solenoid.
  6. Remove the 3 bolts (2) and the EVAP canister (3) from the vehicle.
  7. 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 the 3 bolts (2).
  2. Tighten the EVAP canister bracket support bolts. Tighten: Tighten the bolts to 19 N.m (14 lb ft).
  3. Connect the 3 EVAP hoses (1) to the EVAP canister (3).
  4. Connect the electrical connector (4) to the EVAP pressure switching solenoid.
  5. Connect the EVAP vapor line (1) to the EVAP canister port by pinching both sides of the hose connector (1).
  6. Connect the ORVR vent line (1) to the EVAP canister port by pinching both sides of the hose connector (1).
  7. 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 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).

Note. The EVAP canister may have released carbon particles which caused this part to fail and may cause damage to other components. Check the EVAP canister for loose carbon before returning the vehicle to service.

  1. Remove the EVAP canister (3). Refer to «Evaporative Emission (EVAP) Canister Replacement (FWD)»(ref-200094-S40352068482005102000000) or «Evaporative Emission (EVAP) Canister Replacement (AWD)»(ref-200094-S27752223162005102000000) .
  2. Disconnect the electrical connector of the EVAP pressure switching solenoid.
  3. Disconnect the 2 vapor hoses.
  4. Remove the fastener (2).
  5. Remove the EVAP pressure switching solenoid (1) from the EVAP canister.
  6. Inspect the EVAP pressure switching solenoid and the EVAP control system for carbon particle contamination before replacing the EVAP pressure switching solenoid.
  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 the EVAP pressure switching solenoid (1) to the EVAP canister.
  3. Secure the solenoid with the fastener (2). Tighten: Tighten the fastener to 8.8 N.m (77 lb in).
  4. Connect the 2 vapor hoses.
  5. Connect the electrical connector.
  6. Install the EVAP canister (3). Refer to «Evaporative Emission (EVAP) Canister Replacement (FWD)»(ref-200094-S40352068482005102000000) or «Evaporative Emission (EVAP) Canister Replacement (AWD)»(ref-200094-S27752223162005102000000) .
  1. Remove the 2 fasteners.
  2. Remove the 2 plastic retainers.
  3. Remove the engine cover (1) from the engine.
  4. Disconnect the 4 electrical connectors from the ignition coils (3).
  5. Remove the fasteners (4) from the ignition coils.
  6. Remove the fasteners (2) from the electrical harness (1).
  7. Remove the electrical harness package (1).
  8. 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).
  6. Secure the engine cover (1) with the 2 fasteners. Tighten: Tighten the 2 fasteners to 9 N.m (80 lb in).
  7. Install the 2 plastic retainers.
  1. Remove the 2 clips and the 2 nuts that secure the engine cover to the cylinder head cover.
  2. Remove the engine cover (1) from the cylinder head cover.
  3. Disconnect the electrical connector from each ignition coil.
  4. Remove the bolt (4) securing each ignition coil from the cylinder head cover.
  5. Remove each ignition coil (3) 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-200094-S02001195512005102000000) .
  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: 1.2 mm (0.047 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 cylinder head cover. Secure the engine cover with the 2 clips and the 2 nuts. Tighten: Tighten the nuts to 9 N.m (80 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). Tighten: Tighten the two shield bolts to 10 N.m (89 lb in).
  5. Secure the stone shield (1) with the two bolts (3).
  6. Lower the vehicle.
  1. Remove the 2 fasteners.
  2. Remove the 2 plastic retainers.
  3. Remove the engine cover (1) from the engine.
  4. Disconnect the CMP electrical connector (3).
  5. Remove the 1 CMP sensor hold-down bolt (2).
  6. Remove the CMP sensor (1) from the cylinder head.
  1. Install the CMP sensor (1) into the cylinder head.
  2. Install the 1 CMP sensor hold-down bolt (2). Tighten: Tighten the hold-down bolt to 9 N.m (80 lb in).
  3. Connect the CMP electrical connector (3).
  4. Install the engine cover (1).
  5. Secure the engine cover (1) with the 2 fasteners. Tighten: Tighten the 2 fasteners to 8.8 N.m (77 lb in).
  6. Install the 2 plastic retainers.
  1. Remove the 2 fasteners.
  2. Remove the 2 plastic retainers.
  3. Remove the engine cover (1) from the engine.
  4. Disconnect the electrical connector (1) from the camshaft position (CMP) actuator solenoid valve (2).
  5. Remove the fastener retaining the CMP actuator solenoid valve (1) to the cylinder head.
  6. 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. Install the engine cover (1).
  5. Secure the engine cover (1) with the 2 fasteners. Tighten: Tighten the fasteners to 8.8 N.m (77 lb in).
  6. Install the 2 plastic retainers.
  1. Remove the 2 fasteners from the engine cover.
  2. Remove the 2 plastic retainers from the engine cover.
  3. Remove the engine cover (1) from the engine.
  4. Remove the oil filter plug (3) from the cylinder head.
  5. 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 21 N.m (15 lb ft).
  4. Install the engine cover (1).
  5. Secure the engine cover (1) with the 2 fasteners. Tighten: Tighten the 2 fasteners to 8.8 N.m (77 lb in).
  6. Install the 2 plastic retainers.
  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. 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. Release the two 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 (LV6) - Introduction