Engine Controls - 2.2L (L61) - Introduction: Removal & Installation Saturn ION I

Removal Procedure

Note. In order to prevent any possible electrostatic discharge damage to the ECM, do not touch the connector pins or the soldered components on the circuit board.

Note. Always turn the ignition off when installing or removing the ECM connectors in order to prevent damage to the components.

1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-196956-S04090516432005101000000) in Engine Electrical.
3. Disconnect the small ECM harness connector (3) from the ECM.
4. Remove the bolt retaining the large ECM connector to the ECM.
5. Disconnect the large ECM harness connector (4) from the ECM.
6. Use the retaining tab to release the ECM from the underhood junction block bracket.

Installation Procedure

1. Use the retaining tab to secure the ECM, when installing the ECM to the underhood junction block bracket.
2. Connect the large ECM harness connector (4) to the ECM. Tighten: Tighten the bolt to 4 N.m (35 lb in).
3. Connect the small ECM harness connector (3) to the ECM.
4. Connect the negative Battery Cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-196956-S04090516432005101000000) in Engine Electrical.
5. Program the ECM. Refer to «Control Module References»(ref-196943-S33241539982005101000000) in Computer/Integrating Systems.

Note. Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.

1. Turn OFF the ignition.
2. Drain the coolant system to below the engine coolant temperature (ECT) sensor. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) in Engine Cooling.
3. Disconnect the engine coolant temperature ECT sensor electrical connector.
4. Carefully remove the ECT sensor.

Note. Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage.

Note. Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.

1. If you are reinstalling the original sensor, or if you are installing a new sensor without a sealer, coat the threads with sealer Saturn P/N 21485278 or an equivalent.
2. Install the ECT sensor. Tighten: Tighten the ECT sensor to 10 N.m (89 lb in).
3. Connect the ECT sensor electrical connector.
4. Refill the engine coolant system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) in Engine Cooling.

Scheme 22

Mass Air Flow (MAF) Sensor Replacement

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-196955-S23042070872005101000000) .
2. Disconnect the manifold absolute pressure (MAP) sensor harness connector.
3. Remove the MAP sensor (2) from the intake manifold.
4. Inspect the seal for damage.

1. Install the MAP sensor (2) into the intake manifold.
2. Connect the MAP sensor harness connector.
3. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-196955-S23042070872005101000000) .

Note. The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail connector could affect proper operation of the oxygen sensor.

Note. The use of excessive force may damage the threads in the exhaust manifold/pipe.

1. Remove the exhaust manifold heat shield. Refer to «Exhaust Manifold Replacement (LSJ)»(ref-197010-S21255683592005101000000) or «Exhaust Manifold Replacement (L61)»(ref-197010-S16301056392005101000000) in Engine Exhaust.
2. Disconnect the oxygen sensor harness connector.
3. Remove the oxygen sensor using J 39194-C .

1. Coat the threads of the oxygen sensor with anti-seize compound Saturn P/N 21485279, if necessary.
2. Install the oxygen sensor. Tighten: Tighten the oxygen sensor to 30 N.m (22 lb ft).
3. Connect the oxygen sensor harness connector.
4. Install the exhaust manifold heat shield. Refer to «Exhaust Manifold Replacement (LSJ)»(ref-197010-S21255683592005101000000) or «Exhaust Manifold Replacement (L61)»(ref-197010-S16301056392005101000000) in Engine Exhaust.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
2. Remove the wheel drive shaft heat shield. Refer to «Wheel Drive Shaft Heat Shield Replacement»(ref-197010-S15114761432005101000000) in Engine Exhaust.
3. Note the routing of the HO2S electrical harness.
4. Disconnect the heated oxygen sensor (HO2S) electrical connector (2), in the engine compartment.
5. Carefully bend the edge of the channel on the LH side of the exhaust heat shield outboard, just enough to release the HO2S electrical harness (1).
6. Using the J 39194, carefully remove the HO2S.
7. Lower the HO2S electrical harness away from the underbody.

1. If reinstalling the old heated oxygen sensor (HO2S), coat the threads with anti-seize compound, Saturn P/N 24185279, or equivalent.
2. Carefully install the HO2S to the pipe.
3. Using the J 39194 , or equivalent, tighten the HO2S. Tighten: Tighten the HO2S to 41 N.m (30 lb ft).
4. Install the HO2S electrical harness into position as noted before removal.
5. Carefully bend the edge of the channel (1) on the LH side of the exhaust heat shield inboard, just enough to secure the HO2S electrical harness in the channel.
6. Connect the HO2S electrical connector (2).
7. Install the wheel drive shaft heat shield. Refer to «Wheel Drive Shaft Heat Shield Replacement»(ref-197010-S15114761432005101000000) in Engine Exhaust.
8. Lower the vehicle.

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-196955-S23042070872005101000000) .
2. Disconnect the idle air control (IAC) valve harness connector (1).
3. Remove the IAC valve screw.
4. Remove the IAC valve and seal.

1. Lubricate the IAC valve seal with clean engine oil.
2. Install the IAC valve into the throttle body.
3. Install the IAC valve screw. Tighten: Tighten the IAC valve screw to 3 N.m (27 lb in).
4. Connect the IAC valve harness connector (1).
5. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-196955-S23042070872005101000000) .
6. Reset the IAC valve pintle using the following procedure: Turn ON the ignition, with the engine OFF. Turn OFF the ignition for 10 seconds. Start the engine and check for proper idle operation.

1. Disconnect the connector position assurance (CPA) from the accelerator pedal position (APP) sensor connector.
2. Disconnect the APP sensor harness connector.
3. Remove the APP assembly attachment bolts from the brake pedal assembly.
4. Remove the APP assembly from the vehicle.

1. Install the upper attachment bolt into the APP assembly.
2. Install the APP assembly into the vehicle.
3. Install the attachment bolts into the APP assembly. Tighten: Tighten the accelerator pedal position assembly-to-brake bracket bolt to 9 N.m (80 lb in).
4. Connect the APP sensor harness connector. Push the connector in until the lock position is felt, then pull back to confirm engagement.
5. Install the APP sensor connect CPA.

Note. Do not use solvent of any type when cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as damage to the gasket surfaces and throttle body assembly may result. Use care in cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as sharp tools may damage the gasket surfaces.

Note. Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components.

1. Remove the air cleaner resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-196955-S23042070872005101000000) .
2. Disconnect the idle air control (IAC) valve harness connector (1).
3. Disconnect the throttle position (TP) sensor harness connector (2).
4. Disconnect the vacuum hoses at the throttle body.
5. Remove the throttle body attaching bolts (1).
6. Remove the throttle body (4) from the intake manifold.

1. Inspect the throttle body gasket (3) and replace if necessary.
2. Install the throttle body (4) to the intake manifold.
3. Install the throttle body attaching bolts (1). Tighten: Tighten the throttle body attaching bolts to 10 N.m (89 lb in).
4. Connect the vacuum hoses to the throttle body.
5. Connect the TP sensor harness connector (2).
6. Connect the IAC valve harness connector (1).
7. Install the air cleaner resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-196955-S23042070872005101000000) .
8. Test the accelerator movement by depressing the pedal to the floor and releasing the pedal.

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

1. Remove the cap from the fuel pressure service port connection.
2. Connect the SA9127E , or the J 34730-1A to the fuel pressure service connection. Wrap a shop towel around the fitting while connecting the gage to avoid spillage.
3. Turn the ignition ON, with the engine OFF.
4. Place the bleed hose of the SA9127E , or the J 34730-1A into an approved fuel container.
5. Open the bleed valve on the SA9127E , or the J 34730-1A in order to bleed the air from the fuel pressure gage.
6. Command the fuel pump ON with a scan tool.
7. Close the bleed valve on the SA9127E , or the J 34730-1A .
8. Inspect for fuel leaks.

1. Ensure the fuel pump is OFF.
2. Place the bleed hose of the SA9127E , or the J 34730-1A into an approved fuel container.
3. Open the bleed valve on the SA9127E , or the J 34730-1A in order to bleed the fuel system pressure.
4. Place a shop towel under the fuel pressure service connection to catch any remaining fuel spillage.
5. Remove the SA9127E , or the J 34730-1A from the fuel pressure service connection.
6. Drain any fuel remaining in the SA9127E , or the J 34730-1A into an approved fuel container.
7. Inspect for leaks using the following procedure: Turn the ignition ON, with the engine OFF for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF for 2 seconds. Turn the ignition OFF. Inspect for leaks.
8. Install the cap on the fuel pressure service connection.

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-196955-S27226337802005101000000) .
2. Remove the retainer from the quick-connect fitting, if applicable.
3. Blow dirt out of the fitting using compressed air.
4. Choose the correct tool from J 37088-A tool set for the size of the fitting. Insert the tool into the female connector, then push inward to release the locking tabs.
5. Pull the connection apart.
6. Using a clean shop towel, wipe off the male pipe end.
7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required.

1. Apply a few drops of clean engine oil to the male pipe end.
2. Push both sides of the fitting together to cause the retaining tabs to snap into place.
3. Once installed, pull on both sides of the fitting to make sure the connection is secure.
4. Install the retainer to the quick-connect fitting, if applicable.

1. Blow dirt out of the fitting using compressed air.
2. Depress the tabs on the connector housing in order to release the connector.
3. Continue to depress the tabs while pulling the connector apart.
4. Wipe off the male end using a clean shop towel.
5. Inspect both ends of the fitting for dirt and burrs.
6. Clean or replace the components as required.

1. Apply a few drops of clean engine oil to the male pipe end.
2. Push both sides of the quick-connect fittings together in order to snap the retainer in place.
3. Pull on both sides of the quick-connect fitting in order to make sure the connection is secure.

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-196955-S27226337802005101000000) .
2. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-196955-S28267192132005101000000) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
4. Disconnect the fuel feed and return lines from the fuel filter.
5. Cap or plug the fuel tank feed and return pipes to prevent fuel loss and/or contamination.
6. Disconnect the following evaporative emission (EVAP) pipe fittings, for access to disconnect the fuel filler hose from the tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar) (Press Release)»(ref-196953-S27298530832005101000000) . The EVAP purge pipe (2) from the EVAP canister The fuel tank EVAP vapor pipe (3) from the EVAP canister
7. Cap or plug the EVAP purge (2) and vapor (3) pipes to prevent contamination.
8. Loosen the fuel filler hose clamp (1) at the fuel tank.
9. Disconnect the fuel filler hose from the fuel tank.
10. Disconnect the fuel pump module harness electrical connector from the vehicle underbody connector.
11. Release the exhaust extension pipe insulators (1, 2) from the underbody hangers.
12. Release the muffler insulator (3) from the underbody hanger and slowly lower the exhaust to rest on the rear axle beam.
13. Have an assistant support the fuel tank during fuel tank strap removal, and during tank removal.
14. Remove the LH fuel tank strap bolts and the strap.
15. Remove the RH tank strap bolts and the strap.
16. In order to clear the exhaust extension pipe, slowly lower the RH side of the fuel tank. Use care in feeding the fuel feed and return pipes, the EVAP vapor pipe, and the fuel pump module electrical harness to clear the axle.
17. Once the tank is clear of the RH frame rail, remove the fuel tank down and toward the RH side of the vehicle.
18. If the fuel tank only is to be replaced, remove the fuel pump module assembly from the fuel tank. Refer to «Fuel Pump Module Replacement»(ref-196955-S32923833382005101000000) .

1. If fuel tank replacement was necessary, install the fuel pump module assembly to the fuel tank. Refer to «Fuel Pump Module Replacement»(ref-196955-S32923833382005101000000) .
2. Have an assistant support the fuel tank during fuel tank and fuel tank strap installation.
3. Begin to install the LH side of the fuel tank over the exhaust pipe.
4. Raise the RH side of the fuel tank into position inboard of the RH frame rail. Use care in feeding the fuel feed and return pipes, the EVAP vapor pipe, and the fuel pump module electrical harness over the rear axle.
5. Install the RH fuel tank strap and strap bolts.
6. Install the LH fuel tank strap and strap bolts.
7. Tighten the fuel tank strap bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
8. Raise the exhaust into position and install the muffler insulator (3) to the underbody hanger.
9. Install the exhaust extension pipe insulators (1, 2) to the underbody hangers.
10. Connect the fuel pump module harness electrical connector to the vehicle underbody connector.
11. Connect the fuel filler hose to the fuel tank.
12. Tighten the fuel filler hose clamp (1) at the fuel tank. Tighten: Tighten the clamp to 4.5 N.m (40 lb in).
13. Remove the caps or plugs from the EVAP purge and vapor pipes.
14. Connect the EVAP purge pipe (2) and vapor pipe (3) to the EVAP canister. Refer to «Quick Connect Fitting(s) Service (Plastic Collar) (Press Release)»(ref-196953-S27298530832005101000000) .
15. Remove the caps or plugs from the fuel tank feed and return pipes.
16. Connect the fuel feed and return lines to the fuel filter.
17. Lower the vehicle.
18. Refill the fuel tank.
19. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-196956-S04090516432005101000000) in Engine Electrical.
20. Inspect for fuel leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-196955-S14923477842005101000000) .
2. Disconnect the fuel pump module harness electrical connector from the fuel tank pressure sensor.
3. Position 2 flat-bladed screwdrivers, one on each side of the sensor, near the vacuum port.
4. Carefully use the screwdrivers to lift and release the sensor from the fuel pump module.

1. Install the fuel tank pressure sensor to the fuel pump module assembly. Ensure that the sensor grommet is fully seated to the pump module.
2. Connect the pump module electrical connector to the fuel tank pressure sensor.
3. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-196955-S14923477842005101000000) .

1. Remove the fuel pump module assembly. Refer to «Fuel Pump Module Replacement»(ref-196955-S32923833382005101000000) .
2. Release the fuel level sensor wiring harness from the molded-in tab (1) on the pump module bowl.
3. Disconnect the fuel level sensor electrical connector from the pump module.
4. Depress the retaining tab (2) on the sensor and begin to slide the level sensor away from the pump module.
5. Carefully slide the level sensor the rest of the way off of the pump module.

1. Carefully slide the fuel level sensor into the slots on the fuel pump module bowl.
2. Secure the retaining tab (2) on the sensor into the slot on the pump module bowl.
3. Connect the fuel level sensor electrical connector to the pump module.
4. Install the fuel level sensor wiring harness to the molded-in tab (1) on the pump module bowl.
5. Install the fuel pump module assembly. Refer to «Fuel Pump Module Replacement»(ref-196955-S32923833382005101000000) .

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-196955-S14923477842005101000000) .
2. Release the retaining tab on the fuel tank retainer used to secure the fuel pump module pipes in position on the tank.
3. Release the fuel pump module electrical harness from the retaining slot on the tank.
4. Disconnect the fuel pump module harness electrical connector from the fuel tank pressure sensor.
5. Using the J 39765 (1), carefully rotate to release the fuel pump module retaining lock ring.
6. Remove the fuel pump module retaining lock ring, by sliding the ring over the module pipes and electrical harness.
7. Slowly raise the fuel pump module assembly until the fuel level sensor float arm is just visible. Ensure that the fuel level sensor harness connector clears the tank opening. IMPORTANT: When removing the fuel pump module assembly from the fuel tank, be aware that the pump module reservoir bowl is full of fuel. The reservoir must be tipped slightly during removal to avoid bending the fuel level sensor float arm.
8. Tilt the pump module toward the rear of the fuel tank to enable the level sensor float arm to clear the tank opening. Remove the pump module from the tank.
9. Carefully discard the fuel in the pump module reservoir bowl into an approved fuel container.
10. Remove and discard the fuel pump module-to-fuel tank seal (1).

1. Install a NEW fuel pump module-to-fuel tank seal (1). IMPORTANT: The reservoir must be tipped slightly during installation to avoid bending the fuel level sensor float arm.
2. Tilt the pump module toward the rear of the fuel tank to enable the level sensor float arm to clear the tank opening. Install the fuel pump module to the fuel tank.
3. Slowly lower the fuel pump module assembly into the tank. Ensure that the fuel level sensor harness connector is positioned properly.
4. Install the fuel pump module retaining lock ring over the module pipes and electrical harness, and into position on the top of the module.
5. Using the J 39765 (1), carefully rotate to fully secure the fuel pump module retaining lock ring.
6. Connect the fuel pump module harness electrical connector to the fuel tank pressure sensor.
7. Secure the fuel pump module electrical harness into the retaining slot on the tank.
8. Secure the retaining tab on the fuel tank retainer used to secure the fuel pump module pipes in position on the tank.
9. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-196955-S14923477842005101000000) .

1. Remove the fuel fill cap.
2. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-196955-S28267192132005101000000) .
3. Remove the fuel filler pocket. Refer to «Fuel Filler Pocket Replacement»(ref-196957-S17936294612005101000000) in Body Rear End.
4. Remove the fuel filler pipe assembly upper retaining bolt.
5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
6. Disconnect the evaporative emission (EVAP) vent pipe (1) from the EVAP canister. Refer to «Quick Connect Fitting(s) Service (Plastic Collar) (Press Release)»(ref-196953-S27298530832005101000000) .
7. Loosen the fuel filler hose clamp (1) at the fuel tank.
8. Remove the fuel filler pipe assembly lower retaining bolt.
9. Disconnect the fuel filler hose from the fuel tank.
10. Remove the fuel filler pipe assembly.

1. Install the fuel filler pipe assembly into position on the vehicle.
2. Connect the fuel filler hose to the fuel tank.
3. Install the fuel filler pipe assembly lower retaining bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Tighten the fuel filler hose clamp (1) at the fuel tank. Tighten: Tighten the clamp to 4.5 N.m (40 lb in).
5. Connect the EVAP vent pipe (1) to the EVAP canister. Refer to «Quick Connect Fitting(s) Service (Plastic Collar) (Press Release)»(ref-196953-S27298530832005101000000) .
6. Lower the vehicle.
7. Install the fuel filler pipe assembly upper retaining bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
8. Install the fuel filler pocket. Refer to «Fuel Filler Pocket Replacement»(ref-196957-S17936294612005101000000) in Body Rear End.
9. Refill the fuel tank.
10. Install the fuel fill cap.

1. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-196955-S28267192132005101000000) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
3. Loosen the fuel filler hose clamps (1, 2).
4. Disconnect the fuel filler hose from the fuel tank.
5. Disconnect the fuel filler hose from the fuel filler pipe.

1. Connect the fuel filler hose to the fuel filler pipe.
2. Connect the fuel filler hose to the fuel tank.
3. Tighten the fuel filler hose clamps (1, 2). Tighten: Tighten the clamps to 4.5 N.m (40 lb in).
4. Lower the vehicle.
5. Refill the fuel tank.

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-196955-S27226337802005101000000) .
2. Disconnect the engine fuel feed pipe from the chassis fuel flex hose. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-196955-S32683570782005101000000) .
3. Use a back up wrench on the fuel rail and disconnect the fuel feed pipe.
4. Remove the fuel feed pipe fastener located on the engine.
5. Remove the engine fuel feed pipe.

1. Install the fuel feed pipe to the fuel rail. Tighten: Using a backup wrench on the fuel rail tighten the fuel feed pipe to 10 N.m (89 lb in).
2. Install the engine fuel feed pipe fastener located on the engine. Tighten: Tighten the fuel feed pipe fastener to 10 N.m (89 lb in).
3. Connect the engine fuel feed pipe to the chassis fuel flex hose. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-196955-S32683570782005101000000) .
4. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-196956-S04090516432005101000000) in Engine Electrical.
5. Inspect for leaks using the following procedure: With the engine OFF, turn ON the ignition for 2 seconds. Inspect for fuel leaks. Turn the ignition OFF. With the engine OFF, turn ON the ignition for 2 seconds. Inspect for fuel leaks. Turn the ignition OFF.

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-196955-S27226337802005101000000) .
2. Remove the pipe retaining clip (1) from the fuel feed pipe.
3. Disconnect the fuel feed pipe from the engine fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-196955-S32683570782005101000000) .
4. Cap or plug the fuel pipe and the engine fuel rail to prevent contamination.
5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
6. Remove the evaporative emission (EVAP) canister for pipe removal access. Refer to «Evaporative Emission (EVAP) Canister Replacement»(ref-196955-S21794892672005101000000)
7. Disconnect the fuel filter from the engine feed fuel pipe. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-196955-S32683570782005101000000) .
8. Remove the rear brake pipe bracket retaining nuts and release the brackets from the body studs.
9. Release the pipe retainers (1) from the vehicle underbody.
10. Remove the fuel feed pipe from the pipe retainers.
11. Lower the rear of the pipe while moving the pipe rearward slightly, then lower the front of the pipe.
12. Remove the fuel feed pipe from the vehicle.

1. Position the fuel feed pipe to the vehicle.
2. With the rear of the pipe positioned slightly rearward and down, raise the front of the pipe into position.
3. Install the remainder of the pipe into position.
4. Install the fuel feed pipe to the pipe retainers.
5. Secure the pipe retainers (1) to the vehicle underbody.
6. Install the rear brake hose brackets to the body studs and install the rear brake hose bracket retaining nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
7. Connect the fuel filter to the engine feed fuel pipe (1). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-196955-S32683570782005101000000) .
8. Install the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement»(ref-196955-S21794892672005101000000)
9. Lower the vehicle.
10. Remove the caps or plugs from the fuel pipe and the engine fuel rail.
11. Connect the fuel feed pipe to the engine fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-196955-S32683570782005101000000) .
12. Install the pipe retaining clip (1) to the fuel feed pipe.
13. Connect the negative battery cable.
14. Inspect for fuel leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-196955-S27226337802005101000000) .
2. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-196955-S23042070872005101000000) .
3. Use a back up wrench on the fuel rail and disconnect the fuel supply pipe.
4. Disconnect the fuel injector harness connectors.
5. Remove the fuel rail attaching studs.
6. Remove the fuel rail using the following procedure: Pull the fuel rail back and upward to remove the fuel injectors from the cylinder head ports. Rotate the fuel rail in order to position the injectors downward. Remove the fuel rail.
7. Remove the fuel injectors. Refer to «Fuel Injector Replacement»(ref-196955-S33643661742005101000000) .

1. Install the fuel injectors. Refer to «Fuel Injector Replacement»(ref-196955-S33643661742005101000000) .
2. Install the fuel rail using the following procedure: With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports. Align the injectors by rotating the fuel rail forward. Carefully push the fuel injectors into the cylinder head ports.
3. Install the fuel rail attaching studs. Tighten: Tighten the fuel rail studs to 10 N.m (89 lb in).
4. Connect the fuel injector harness connectors. Pull back to insure the connectors are locked in place.
5. Install the fuel supply pipe. Tighten: Using a backup wrench on the fuel rail tighten the fuel supply pipe to 10 N.m (89 lb in).
6. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-196955-S23042070872005101000000) .
7. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-196956-S04090516432005101000000) in Engine Electrical.
8. Inspect for fuel leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.

1. Remove the fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-196955-S03175512062005101000000) .
2. Remove the fuel injector retainer clip (3).
3. Remove the fuel injectors (5) from the fuel rail.
4. Remove and discard the fuel injector O-rings (4, 7).

1. Install the O-rings on the fuel injector (4, 7).
2. Install the fuel injector clip (3) on the fuel injector (5).
3. Install the fuel injector in the fuel rail with the connector facing upward.
4. Install the fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-196955-S03175512062005101000000) .

1. Disconnect the evaporative emission (EVAP) canister purge valve harness connector.
2. Disconnect the vacuum pipe from the EVAP canister purge valve.
3. Disconnect the purge pipe from the EVAP canister purge valve.
4. Remove the EVAP canister purge valve and bracket.
5. Remove the EVAP canister purge valve from the purge bracket.
6. Inspect for carbon release in the EVAP canister purge valve ports. Refer to «Evaporative Emission (EVAP) System Cleaning»(ref-196955-S06727566852005101000000) .

1. Install the EVAP canister purge valve on to the purge bracket.
2. Install the EVAP canister purge valve and bracket. Tighten: Tighten the purge bracket nut to 8 N.m (71 lb in).
3. Connect the purge pipe to the EVAP canister purge valve.
4. Connect the vacuum pipe to the EVAP canister purge valve.
5. Connect the EVAP canister purge valve harness connector.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
2. Disconnect the electrical connector from the evaporative emission (EVAP) canister vent solenoid valve.
3. Clean away any debris that may be present around the EVAP canister vent valve.
4. Remove the EVAP canister retaining bolt (1).
5. Lower the EVAP canister.
6. Rotate the EVAP canister vent valve counterclockwise to release from the locked position.
7. Remove the vent valve from the EVAP canister.

1. Insert the EVAP canister vent solenoid valve into the EVAP canister, with the valve aligned to the released position.
2. Rotate vent valve clockwise to secure into the locked position.
3. Install the EVAP canister and retaining bolt (1). Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Connect the electrical connector to the EVAP canister vent valve.
5. Lower the vehicle.

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-196955-S35764149722005101000000) .
2. Disconnect the engine purge pipe (1) from the evaporative emission (EVAP) canister purge valve (2).
3. Disconnect the engine purge pipe (1) from the intake manifold.
4. Remove the engine purge pipe (1).

1. Position the engine purge pipe (1) to the EVAP canister purge valve (2) and the intake manifold.
2. Connect the engine purge pipe (1) to the intake manifold.
3. Connect the engine purge pipe (1) to the EVAP canister purge valve (2).
4. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-196955-S35764149722005101000000) .

1. Disconnect the EVAP purge pipe from the engine purge hose. Refer to «Quick Connect Fitting(s) Service (Plastic Collar) (Press Release)»(ref-196953-S27298530832005101000000) .
2. Cap or plug the purge pipe and the engine purge hose to prevent contamination.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
4. Remove the evaporative emission (EVAP) canister for pipe removal access. Refer to «Evaporative Emission (EVAP) Canister Replacement»(ref-196955-S21794892672005101000000) .
5. Remove the rear brake pipe bracket retaining nuts and release the brackets from the body studs.
6. Release the pipe retainers (1) from the vehicle underbody.
7. Remove the purge pipe from the pipe retainers.
8. Lower the rear of the pipe while moving the pipe rearward slightly, then lower the front of the pipe.
9. Remove the purge pipe from the vehicle.

1. Position the purge pipe to the vehicle.
2. With the rear of the pipe positioned slightly rearward and down, raise the front of the pipe into position.
3. Install the remainder of the pipe into position.
4. Install the purge pipe to the pipe retainers.
5. Secure the pipe retainers (1) to the vehicle underbody.
6. Install the rear brake hose brackets to the body studs and install the rear brake hose bracket retaining nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
7. Install the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement»(ref-196955-S21794892672005101000000) .
8. Lower the vehicle.
9. Remove the caps or plugs from the purge pipe and the engine purge hose.
10. Connect the purge pipe to the engine purge hose. Refer to «Quick Connect Fitting(s) Service (Plastic Collar) (Press Release)»(ref-196953-S27298530832005101000000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
2. Disconnect the electrical connector from the evaporative emission (EVAP) canister vent solenoid valve.
3. Disconnect the hose connections (1, 2, 3) from the EVAP canister. Refer to «Quick Connect Fitting(s) Service (Plastic Collar) (Press Release)»(ref-196953-S27298530832005101000000) .
4. Remove the EVAP canister retaining bolt (1).
5. Remove the EVAP canister assembly toward the outboard side of the vehicle.
6. If the EVAP canister is to be reused, inspect the canister for loose carbon.

1. Insert the retaining tab of the EVAP canister into the slotted bracket on the vehicle underbody.
2. Install the EVAP canister retaining bolt (1). Tighten: Tighten the bolt to 10 N.m (89 lb in).
3. Connect the hose connections (1,2,3) to the EVAP canister. Refer to «Quick Connect Fitting(s) Service (Plastic Collar) (Press Release)»(ref-196953-S27298530832005101000000) .
4. Connect the electrical connector to the EVAP canister vent solenoid valve.
5. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
2. Clean away any debris that may be present around the evaporative emission (EVAP) canister vent filter cover.
3. Carefully release the canister filter cover rear retaining tabs.
4. Carefully release the canister filter cover forward retaining tabs and remove the cover from the EVAP canister.
5. Remove the filter from the canister and discard the filter.
6. Remove the seal from the filter cover and discard the seal.
7. Clean the inside of the EVAP canister filter housing with a clean shop towel.

1. Install a NEW cover to the canister. Ensure that the seal is properly seated to the cover.
2. Install a NEW filter to the canister filter housing.
3. Install the filter cover to the EVAP canister.
4. Lower the vehicle.

1. Remove the accelerator and cruise control cables from the bracket, if equipped.
2. Remove the bracket.
3. Remove the ignition control module (ICM). Refer to «Ignition Control Module Replacement»(ref-196955-S09936001132005101000000) .
4. Remove the ignition coil housing retaining bolts.
5. Remove the ignition coil housing from the camshaft cover.

1. Install the ignition coil housing to the camshaft cover.
2. Install the ignition coil housing retaining bolts. Tighten: Tighten the retaining bolts to 10 N.m (89 lb in).
3. Install the ICM. Refer to «Ignition Control Module Replacement»(ref-196955-S09936001132005101000000) .
4. Install the accelerator and cruise control cables bracket.
5. Install the accelerator and cruise control cables bracket bolts. Tighten: Tighten the retaining bolts to 10 N.m (89 lb in).
6. Install the accelerator and cruise control cables to the bracket.

1. Turn OFF the ignition.
2. Remove the accelerator cable from the bracket.
3. Remove the accelerator cable bracket bolt.
4. Remove the accelerator cable bracket.
5. Disconnect the ignition control module (ICM) harness connector.
6. Remove the ICM retaining screws.
7. Remove the ICM from the ignition coil housing.

1. Install the ignition control module in the ignition coil housing.
2. Install the ICM retaining screws. Tighten: Tighten the retaining screws to 1.5 N.m (13 lb in).
3. Connect the ICM harness connector.
4. Install the accelerator cable bracket.
5. Install the accelerator cable bracket bolt. Tighten: Tighten the retaining screws to 10 N.m (18 lb in).
6. Install the accelerator cable to the bracket.

Note. This engine has aluminum cylinder heads. Do not remove the spark plugs from a hot engine, allow it to cool first. Removing the spark plugs from a hot engine may cause spark plug thread damage or cylinder head damage.

1. Remove the ignition coil housing. Refer to «Ignition Coil Housing Replacement»(ref-196955-S12855795932005101000000) .
2. Remove the spark plugs with a spark plug socket.
3. Inspect the spark plugs. Refer to «Spark Plug Inspection»(ref-196955-S35766263312005101000000) .

1. Gap the spark plug, using round wire type spark plug gap gage. Gap: Adjust the spark plug gap to 1.14 mm (0.045 in).
2. Install the spark plugs with a spark plug socket. Tighten: Tighten the spark plugs to 20 N.m (15 lb ft).
3. Install the ignition coil housing. Refer to «Ignition Coil Housing Replacement»(ref-196955-S12855795932005101000000) .

1. Remove the starter. Refer to «Starter Motor Replacement (2.2L (L61))»(ref-196956-S11465160332005101000000) or «Starter Motor Replacement (2.0L (LSJ))»(ref-196956-S27966625002005101000000) in Engine Electrical.
2. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
3. Remove the CKP sensor bolt.
4. Remove the CKP sensor.

1. Inspect the CKP sensor O-ring and lubricate with a mineral based grease.
2. Gently insert the CKP sensor into the block.
3. Install the CKP sensor bolt. Tighten: Tighten the CKP sensor bolt to 8 N.m (71 lb in).
4. Reconnect the CKP sensor electrical connector.
5. Install the starter. Refer to «Starter Motor Replacement (2.2L (L61))»(ref-196956-S11465160332005101000000) or «Starter Motor Replacement (2.0L (LSJ))»(ref-196956-S27966625002005101000000) in Engine Electrical.
6. Perform the CKP system Variation Learn Procedure. Refer to «CKP System Variation Learn Procedure»(ref-196955-S00053011772005101000000) .

1. Remove the starter. Refer to «Starter Motor Replacement (2.2L (L61))»(ref-196956-S11465160332005101000000) or «Starter Motor Replacement (2.0L (LSJ))»(ref-196956-S27966625002005101000000) in Engine Electrical.
2. Disconnect the knock sensor (KS) harness connector.
3. Remove the KS retaining bolt.
4. Remove the KS.

1. Install the knock sensor. Tighten: Tighten the knock sensor retaining bolt to 25 N.m (18 lb ft).
2. Connect the knock sensor harness connector.
3. Install the starter. Refer to «Starter Motor Replacement (2.2L (L61))»(ref-196956-S11465160332005101000000) or «Starter Motor Replacement (2.0L (LSJ))»(ref-196956-S27966625002005101000000) in Engine Electrical.

1. Disconnect the intake air temperature (IAT) sensor harness connector.
2. Loosen the air cleaner assembly clamp.
3. Disconnect the air cleaner assembly clips.
4. Remove the upper air cleaner cover.
5. Remove the air cleaner filter from the lower air cleaner housing.
6. Inspect the air cleaner filter for dust, dirt, and water contamination.
7. Replace as necessary. Refer to «Maintenance Schedule»(ref-197013-S28119388212005101000000) in Maintenance and Lubrication.

1. Install the air cleaner filter into the lower air cleaner housing.
2. Install the upper air cleaner cover to the lower air cleaner housing.
3. Secure the air cleaner housing cover.
4. Connect the air cleaner resonator to the air cleaner assembly. Tighten: Tighten the air cleaner intake duct clamp to 5 N.m (44 lb in).
5. Connect the IAT sensor harness connector.

1. Loosen the outlet duct clamp at the air cleaner assembly.
2. Remove the air cleaner assembly attachment nut.
3. Remove the air cleaner.

1. Position the air cleaner assembly.
2. Install the air cleaner assembly attachment nut. Tighten: Tighten the nut to 10 N.m (89 lb in).
3. Connect the air cleaner resonator to the air cleaner assembly. Tighten: Tighten the air cleaner intake duct clamp to 5 N.m (44 lb in).

1. Disconnect the intake air temperature (IAT) sensor harness connector.
2. Loosen the air cleaner assembly fresh air duct to resonator clamp.
3. Remove the push-pin fastener from the air outlet resonator/duct assembly to support bracket.
4. Loosen the resonator to throttle body clamp.
5. Disconnect the air cleaner assembly fresh air duct from the resonator.
6. Remove the air outlet resonator from the throttle body.

1. Install the air outlet resonator to the throttle body.
2. Connect the fresh air duct to the air outlet resonator.
3. Tighten the air outlet resonator to throttle body clamp. Tighten: Tighten the clamp to 5 N.m (44 lb in).
4. Align the air outlet resonator to the bracket and install the push-pin fastener.
5. Connect the air cleaner assembly fresh air duct to the air outlet resonator. Tighten: Tighten the clamp to 5 N.m (44 lb in).
6. Connect the IAT sensor harness connector.

1. Remove the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-196968-S42694341792005101000000) in Tire and Wheels.
2. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(ref-196958-S29238524142005101000000) in Body Front End.
3. Remove the air cleaner intake duct assembly push-in fasteners.
4. Remove the air cleaner intake duct assembly bolt.
5. Remove the intake duct assembly from the vehicle.

1. Position the intake duct assembly.
2. Install the intake duct assembly bolt. Tighten: Tighten the bolt to 10 N.m (89 lb ft).
3. Install the intake duct assembly push in fasteners.
4. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(ref-196958-S29238524142005101000000) in Body Front End.
5. Install the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-196968-S42694341792005101000000) in Tire and Wheels.