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

Engine Control Module (ECM) Replacement

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 in Engine Electrical.
3. Disconnect the intake air temperature (IAT) sensor.
4. Loosen the clamp at the air cleaner assembly.
5. Remove the push pin attachment from the outlet resonator/duct assembly to support bracket.
6. Loosen the clamp at the throttle body assembly.
7. Disconnect the PCV fresh air hose at the cam cover.
8. Remove the outlet resonator/duct assembly.
9. Remove the J 1 and J 2 connectors at the ECM.
10. Remove the 4 ECM attachment bolts.

Installation Procedure

1. Install the ECM.
2. Install the ECM bolts. Tighten: Tighten the engine control module bolts to 8 N.m (71 lb in).
3. Connect the J 1 and J 2 ECM electrical connectors.
4. Install the outlet resonator/duct assembly into position.
5. Connect the PCV fresh air vent hose assembly.
6. Tighten the clamp at the throttle body assembly.
7. Position the outlet resonator/duct assembly up with the support bracket and install the push-pin.
8. Tighten the clamp at the air cleaner assembly.
9. Connect the intake air temperature (IAT) sensor connector.
10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
11. Reprogram the ECM. Refer to Service Programming System (SPS) in Programming.
12. Perform the Passlock Relearn Procedure using the Service Stall System (SSS).
13. Turn the ignition to OFF for 10 seconds.
14. Perform the crankshaft relearn procedure. Refer to CKP System Variation Learn Procedure .
15. Verify no DTCs exist. If one exists, refer to the specific DTC diagnostic.

Removal Procedure

1. Turn the ignition OFF.
2. Disconnect the ECT sensor harness connector.
3. Remove the ECT.

1. Apply thread sealant Saturn P/N 21485277 Loctite 242® Threadlocker, or equivalent, to sensor threads.
2. Install the ECT sensor. Tighten: Tighten the engine coolant temperature sensor to 10 N.m (89 lb in).
3. Connect the ECT sensor harness connector. Push in the connector until a click is heard, then pull back to confirm a positive engagement.
4. Fill engine coolant to proper level. Refer to Draining and Filling Cooling System in Engine Cooling.

1. Turn the ignition OFF.
2. Disconnect the IAT sensor harness connector.
3. Remove the IAT sensor by pulling it out of the air induction tube.

1. Install the IAT sensor.
2. Connect the IAT sensor harness connector. Push in the connector until a click is heard, then pull back to confirm a positive engagement.

1. Disconnect the intake air temperature (IAT) sensor connector.
2. Loosen the clamp at the air cleaner assembly.
3. Remove the push-pin attachment from the outlet resonator/duct assembly to support bracket.
4. Loosen the clamp at the throttle body assembly.
5. Disconnect the PCV fresh air vent hose at the cam cover.
6. Remove the outlet resonator/duct assembly.
7. Disconnect the MAP sensor electrical connector.
8. Remove the MAP sensor and the MAP sensor port seal if it is still retained in the intake manifold.

1. Install the MAP sensor with port seal into the intake manifold.
2. Connect the MAP sensor electrical connector. Push in the connector until a click is heard and pull back to confirm a positive engagement.
3. Install the outlet resonator/duct assembly into position.
4. Connect the PCV fresh air vent hose assembly.
5. Tighten the clamp at the throttle body assembly. Tighten: Tighten the clamp to 4 N.m (36 lb in).
6. Position the outlet resonator/duct assembly up with the support bracket and install the push-pin.
7. Tighten the clamp at the air cleaner assembly. Tighten: Tighten the clamp to 4 N.m (36 lb in).
8. Connect the IAT sensor connector.

1. Turn the ignition OFF.
2. Disconnect the HO2S-1 harness connector.
3. Remove the sensor harness and connector from the attachment clip.
4. Use a liquid penetrate before removing the sensor.
5. Remove the H02S-1 using the J 39194-C , or equivalent. See Special Tools and Equipment .

1. Apply a small amount of anti-seize compound Saturn P/N 21485279, or equivalent, to the threads of the HO2S-1.
2. Install the HO2S-1 using the J 39194-C , or equivalent. See Special Tools and Equipment . Tighten: Tighten the oxygen sensor-to-exhaust manifold pipe to 45 N.m (33 lb ft).
3. Install the sensor harness and connector to the attachment clip.
4. Connect the HO2S-1 harness connector. Push in the connector until a click is heard and pull back to confirm a positive engagement.

1. Turn the ignition OFF.
2. Raise the vehicle.
3. Disconnect the HO2S-2 harness connector.
4. Remove the HO2S-2 harness clip from the heat shield attachment.
5. Use a liquid penetrate before removing the sensor.
6. Remove the HO2S-2 using the J 39194-C , or equivalent. See Special Tools and Equipment .

1. Apply a small amount of anti-seize compound Saturn P/N 21485279, or equivalent, to the threads of the HO2S-2.
2. Install the HO2S-2 using the J 39194-C , or equivalent. See Special Tools and Equipment . Tighten: Tighten the HO2S-2 sensor-to-exhaust pipe to 45 N.m (33 lb ft).
3. Install the HO2S-2 harness clip to the heat shield attachment bolt. Tighten: Tighten the bolt to 4 N.m (35 lb in).
4. Connect the HO2S-2 harness connector. Push in the connector until a click is heard, then pull back to confirm a positive engagement.
5. Ensure the HO2S-2 harness pigtail connector is secure to the chassis.

1. Disconnect the connector position assurance (CPS) from the accelerator pedal position (APP) sensor connector.
2. Disconnect the APP sensor harness connector.
3. Remove the APP assembly attachment bolts to 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 25 N.m (18 lb ft).
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.

1. Disconnect the intake air temperature (IAT) sensor connector.
2. Loosen the clamp a the air cleaner assembly.
3. Remove the push pin attachment from the outlet resonator/duct assembly to support bracket.
4. Loosen the clamp at the throttle body assembly.
5. Disconnect the PCV fresh air vent hose at the cam cover.
6. Remove the outlet resonator/duct assembly.
7. Cover the throttle body opening with a shop towel and use the shop air to remove any dirt at the base of the throttle body.
8. Disconnect the electrical connector at throttle body.
9. Remove the throttle body bolts.
10. Remove the throttle body.
11. Remove the gasket and discard.
12. Block the intake manifold opening with a clean shop towel to prevent dirt from entering.

1. Remove the shop towel from the throttle body opening.
2. Install the throttle body gasket.
3. Install the throttle body assembly and bolts. Tighten: Tighten the throttle body-to-intake manifold bolts - L61 to 10 N.m (89 lb in).
4. Connect the throttle body electrical connector.
5. Position the outlet resonator/duct assembly into position.
6. Connect PCV fresh air vent hose assembly.
7. Tighten the clamp at throttle body assembly.
8. Position the outlet resonator/duct assembly up with support bracket and install the push-pin.
9. Tighten the clamp at the air cleaner assembly.
10. Connect the intake air temperature (IAT) sensor connector.
11. Turn the ignition ON for one minute while the engine control module (ECM) automatically relearns throttle position.

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. Install the J 34730-1A to the fuel pressure connection, located on the fuel rail. See Special Tools and Equipment .
2. Place the bleed hose of the fuel pressure gage into an approved gasoline container.
3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the gage.
4. Turn ON the ignition, with the engine OFF.
5. Command the fuel pump ON with a scan tool until all of the air is bled out of the gage.
6. Close the bleed valve on the fuel pressure gage.
7. Command the fuel pump ON with a scan tool.
8. Inspect for fuel leaks.

1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure.
2. Place a shop towel under the fuel pressure gage to catch any remaining fuel spillage.
3. Remove the J 34730-1A from fuel pressure connection. See Special Tools and Equipment .
4. Drain any fuel remaining in the fuel pressure gage into an approved container.
5. Install the cap on the fuel pressure connection.
6. Place the shop towel in an approved container.

Fuel Injectors and Fuel Rail Replacement

Tools Required

1. SA9127E Gage Bar Set
2. SA9805E Fuel Line Separator

1. Disconnect the negative battery cable.
2. Disconnect the intake air temperature (IAT) sensor connector.
3. Loosen the clamp at the air cleaner assembly.
4. Remove the push pin attachment from the outlet resonator/duct assembly to support bracket.
5. Loosen the clamp at the throttle body assembly.
6. Disconnect the PCV fresh air vent hose at the cam cover.
7. Remove the outlet resonator/duct assembly.
8. Place a shop rag over the throttle body assembly.
9. Using shop air, blow off the dirt and dust near the fuel injector ports.
10. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
11. Disconnect the SA9127E after the pressure has been relieved.
12. Position the engine harness away from the fuel rail assembly.
13. Disconnect the fuel rail bracket and nut at the rear of the cam cover.
14. Disengage the fuel transfer lines at quick contract from the fuel line using the SA9805E .
15. While supporting the fuel rail assembly with an open-end wrench, loosen the transfer line fitting at the fuel rail.
16. Position the fuel line away from the rail assembly without disconnecting the degas hose.
17. Disconnect the electrical connectors at the fuel injectors.
18. Remove the fuel rail assembly attachment bolts.
19. Remove the fuel rail assembly by carefully pulling the rail backward and upward to remove injectors from the cylinder head.
20. Move the fuel rail assembly rearward while slightly rotating to remove the fuel rail assembly.
21. Remove the fuel injector retaining clips (3).
22. Remove the fuel injectors (5) from the fuel rail.
23. Remove and discard all injector O-ring seals (4, 7) by using a small pick.

1. Transfer components to the new fuel rail if the rail is being replaced.
2. Install the new upper and lower O-ring seals (4, 7) to injectors (5).
3. Install the injectors (5) to the fuel rail assembly.
4. Install the isolators (6) with new seals to injectors.
5. Install the injector retaining clip (3).
6. Install the fuel rail to the cylinder head.
7. Install the fuel rail bolts. Tighten: Tighten the fuel rail-to-cylinder head L61 to 10 N.m (89 lb in).
8. Position the fuel line assembly.
9. Install the fuel line bracket and bracket bolt. Tighten: Tighten the transfer line fitting-to-fuel rail L61 to 10 N.m (89 lb in).
10. Connect the fuel rail bracket and nut to the cylinder head. Tighten: Tighten the fuel line bracket bolt L61 to 10 N.m (89 lb in).
11. Connect the fuel line to transfer line.
12. Insert the fuel transfer line into the fuel line connection. An audible click should be heard.
13. Remove the shop towel from the throttle body.
14. Install the outlet resonator/duct assembly into position.
15. Connect the PCV fresh air bent hose assembly.
16. Tighten the clamp at the throttle body assembly.
17. Position the outlet resonator/duct assembly up with a support bracket and install the push pin.
18. Tighten the clamp at the air cleaner assembly.
19. Connect the intake air temperature (IAT) sensor connector.
20. Connect the negative battery cable. Tighten: Tighten the battery terminal bolts to 17 N.m (13 lb ft).

1. Remove the fuel tank. Refer to Fuel Tank Replacement .
2. Disconnect the evaporative emission (EVAP) vent line quick connect.
3. Use the SA9156E and remove the fuel pump module retaining ring. See Special Tools and Equipment .
4. Disconnect the secondary level sensor electrical connector.
5. Disconnect the suction port attaching tube by pressing down on the tab (1).
6. Remove the secondary fuel pump module.
7. Discard the fuel pump module-to-tank seal.
8. If the fuel level sending unit is being replaced as well, remove the fuel level sender. Refer to Fuel Level Sensor Replacement - Secondary .

1. If the fuel level sending unit is being replaced, install the fuel level sending unit into the new fuel pump. Refer to Fuel Level Sensor Replacement - Secondary .
2. Connect the suction port (1).
3. Insert the new secondary fuel pump module with the level sender and new fuel pump-to-tank seal. Ensure the orientation tabs are aligned.
4. Use the SA9156E to install the fuel pump lock ring. See Special Tools and Equipment .
5. Connect the EVAP line quick connect.
6. Install the fuel tank. Refer to Fuel Tank Replacement .

1. Remove the fuel tank. Refer to Fuel Tank Replacement .
2. Remove the secondary fuel pump module. Refer to Fuel Tank Module Replacement - Secondary .
3. Disconnect the electrical connectors from the primary fuel pump module and fuel tank pressure sensor.
4. Use the J 45722 and remove the fuel pump module retaining ring. See Special Tools and Equipment .
5. Disconnect the fuel feed and vent lines from the fuel tank.
6. Remove the primary fuel pump module assembly.
7. Discard the fuel pump module-to-tank seal.
8. If the fuel level sending unit is being replaced, remove the fuel level sender. Refer to Fuel Level Sensor Replacement - Primary .

1. If the fuel level sending unit is being replaced, install the fuel level sending unit onto the new fuel pump. Refer to Fuel Level Sensor Replacement - Primary .
2. Insert the new primary fuel pump module assembly with the level sender and the new fuel pump-to-tank seal. Ensure the orientation tabs are aligned.
3. Use the J 45722 to install the fuel pump lock ring. See Special Tools and Equipment .
4. Connect the wiring harness to the primary fuel pump module and fuel tank pressure sensor.
5. Install the secondary fuel pump module. Refer to Fuel Tank Module Replacement - Secondary .
6. Install the fuel tank. Refer to Fuel Tank Replacement .

Fuel Rail Transfer Line Replacement

Tools Required

1. SA9127E Gage Bar Set
2. SA9805E Fuel Line Separator

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
2. Disconnect the intake air temperature (IAT) sensor connector.
3. Loosen the clamp at the air cleaner assembly.
4. Remove the push pin attachment from the outlet resonator/duct assembly to support bracket.
5. Loosen the clamp at the throttle body assembly.
6. Disconnect the PCV fresh air vent hose at cam cover.
7. Remove the outlet resonator/duct assembly.
8. Cover the throttle body opening with a shop towel. Use shop air to remove any dirt near the transfer line connection.
9. Remove any electrical harness or hoses that may be attached to the transfer line.
10. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
11. Disconnect the SA9127E after the pressure has been relieved.
12. Disconnect the fuel rail bracket and bolt at the rear of the camshaft cover.
13. Disconnect the fuel transfer at quick connect from the fuel line using the SA9805E .
14. While supporting the fuel rail assembly with an open-end wrench, loosen the transfer line fitting at fuel rail.
15. Remove the fuel transfer line.
16. Visually inspect the O-ring seals for cuts, nicks, or flatness. Replace as necessary.

1. Properly position the fuel transfer line assembly.
2. Install the transfer line assembly with an O-seal to fuel rail assembly and hand tighten.
3. Connect the fuel rail bracket and nut to the cylinder head. Tighten: Tighten the fuel line bracket-to-cylinder head bolt to 10 N.m (89 lb in).
4. Tighten the transfer line fitting at fuel rail. Tighten: Tighten the fuel transfer line fitting-to-fuel rail 4 cylinder to 10 N.m (89 lb in).
5. Insert the fuel transfer line into the fuel line connection. An audible click should be heard. Pull rearward to fully seat the connection.
6. Remove the shop towel from the throttle body.
7. Connect any electrical harness or hoses that have been disconnected from the transfer line.
8. Install the outlet resonator/duct assembly into position.
9. Connect the PCV fresh air bent hose assembly.
10. Tighten the clamp at the throttle body assembly.
11. Position the outlet resonator/duct assembly up with a support bracket and install the push pin.
12. Tighten the clamp at the air cleaner assembly.
13. Connect the intake air temperature (IAT) sensor connector.
14. Connect the negative battery cable. Tighten: Tighten the battery terminal bolts to 17 N.m (13 lb ft).

1. Disconnect the negative battery cable.
2. Disconnect the intake air temperature (IAT) sensor connector.
3. Loosen the clamp at the air cleaner assembly.
4. Remove the push pin attachment from the outlet resonator/duct assembly to support bracket.
5. Loosen the clamp at the throttle body assembly.
6. Disconnect the PCV fresh air vent hose at the cam cover.
7. Remove the outlet resonator/duct assembly.
8. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
9. Disconnect the SA9127E after the pressure has been relieved.
10. Remove the fuel dampener bolts.
11. Remove the fuel pressure dampener and O-ring seals.
12. Visually inspect the seals for cuts, nicks, or flatness. Replace as necessary.

1. Install the small oiled O-ring (4) into the fuel rail.
2. Install the large oiled O-ring (7) into the fuel rail.
3. Install the fuel pressure regulator into the fuel rail.
4. Install the retaining bolts. Tighten: Tighten the fuel pressure dampener bolts to 5 N.m (44 lb in).
5. Install the outlet resonator/duct assembly into position.
6. Connect the PCV fresh air vent hose assembly.
7. Tighten the clamp at the throttle body assembly.
8. Position the outlet resonator/duct assembly up with a support bracket and install the push pin.
9. Tighten the clamp at the air cleaner assembly.
10. Connect the air intake temperature (IAT) sensor connector.
11. Connect the negative battery cable. Tighten: Tighten the battery terminal bolt to 17 N.m (13 lb ft).
12. Run the vehicle and inspect for leaks.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
2. Blow dirt out of the fitting using compressed air.
3. Squeeze the plastic tabs of the male end connector.
4. Pull the connection apart.
5. Wipe off the male pipe end using a clean shop towel.
6. Inspect both ends of the fitting for dirt and burrs.
7. 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 fitting together in order to cause the retaining tabs to snap into place.
3. Pull on both sides of the quick connect fitting in order to make sure the connection is secure.

1. Ensure that the fuel level in the tank is less than 1/4 full. If necessary, drain the fuel tank to at least this level. Refer to Fuel Tank Draining Procedure .
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the rubber exhaust hangers on order to allow the exhaust system to drop slightly.
6. Remove the propeller shaft, if equipped. Refer to Propeller Shaft Replacement in Propeller Shaft.
7. Disconnect the evaporative emission (EVAP) canister vent and fresh air hoses: Grasping both sides of the quick-connect fitting, twist the female connector 1/4 turn in each direction in order to loosen dirt within the quick-connect fitting. Blow any dirt out of the quick-connect fitting using compressed air. Squeeze the plastic retainer release tabs. Pull the connection apart. Inspect both ends of the quick-connect fitting for dirt and burrs.
8. Remove the fuel filler pipe, EVAP vent hose, and fresh air hose from the fuel tank.
9. Disconnect the chassis fuel supply line from the tank.
10. Disconnect the electrical connectors: Fuel tank electrical connectors EVAP solenoid electrical connector
11. Support the fuel tank.
12. Remove the fuel tank strap bolts and fuel tank straps.
13. Lower the fuel tank from the underbody of the vehicle.
14. Remove the fuel tank module assemblies. Refer to Fuel Tank Module Replacement - Primary and Fuel Tank Module Replacement - Secondary .

1. Install the fuel tank module assemblies. Refer to Fuel Tank Module Replacement - Primary and Fuel Tank Module Replacement - Secondary .
2. Install the fuel tank heat shield and fuel tank assembly into the vehicle.
3. Install the fuel tank straps and tighten the bolts. Tighten: Tighten the fuel tank strap-to-body bolts to 25 N.m (18 lb ft).
4. Install the fuel filler pipe, EVAP vent, and fresh air hoses to the fuel tank.
5. Connect the electrical connectors: Fuel tank electrical connector EVAP solenoid electrical connectors
6. Tighten the hose clamp on the filler pipe-to-fuel tank connecting hose. Tighten: Tighten the fuel fill neck-to-fuel tank clamp to 5 N.m (44 lb in).
7. Connect the EVAP canister vent and fresh air hoses to the fuel tank hoses.
8. If equipped, install the propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft.
9. Install the rubber exhaust hangers.
10. Lower the vehicle.
11. Fill the fuel tank with gasoline.
12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
13. Prime the fuel system: Cycle the ignition ON for 5 seconds and then OFF for 10 seconds. Repeat the previous step twice. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds. If the engine does not start, repeat steps 13.1-13.3.

1. Remove the fuel tank. Refer to Fuel Tank Replacement .
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 .

1. Remove the fuel tank. Refer to Fuel Tank Replacement .
2. Remove the fuel pump module. Refer to Fuel Tank Module Replacement - Primary .
3. Disconnect the fuel level sender unit and float electrical connector from the underside of the top of the pump module.
4. Release the retaining tabs (1, 2) and remove the level sensor by sliding up.

1. Install the fuel level sender unit and float onto the fuel pump module. Make sure that the sender cap snaps into place (1, 2).
2. Connect the fuel level sender unit and float electrical connector.
3. Install the fuel pump module into the fuel tank. Refer to Fuel Tank Module Replacement - Primary .
4. Install the fuel tank. Refer to Fuel Tank Replacement .

1. Remove the fuel tank. Refer to Fuel Tank Replacement .
2. Remove the fuel pump module. Refer to Fuel Tank Module Replacement - Secondary .
3. Disconnect the fuel level sender unit and the float electrical connector.
4. Release the retaining tabs and remove the level sensor by sliding up.

1. Install the fuel level sender unit and float onto the fuel pump module. Make sure that the sender cap snaps into place.
2. Connect the fuel level sender unit and the float electrical connector.
3. Install the fuel pump module into the fuel tank. Refer to Fuel Tank Module Replacement - Secondary .
4. Install the fuel tank. Refer to Fuel Tank Replacement .

1. Ensure that the fuel level in the tank is less than 1/4 full. If necessary, drain the fuel tank to at least this level. Refer to Fuel Tank Draining Procedure .
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
3. Remove the fuel filler cap.
4. Push/pry the closeout grommet to expose the fuel fill neck attachment bolt. Remove the fill neck attachment bolt.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
6. Remove the right rear wheel and tire. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
7. Remove the right rear wheelhouse inner liner. Refer to Wheelhouse Liner Panel Replacement - Rear in Body Rear End.
8. Remove the fuel filler pipe intermediate bracket bolt.
9. Disengage the fuel filler neck from the support bracket by moving the fuel filter neck up and to the left, toward the rear of the vehicle.
10. Disconnect the fuel fill pipe vent tube, fresh air hose, and fuel fill hose from the fuel tank.
11. Disengage the filler pipe hose from the fuel tank and remove the fuel filler pipe and rubber grommet from the vehicle.

1. Install the rubber grommet onto the fuel filler pipe.
2. Position the filler pipe into the wheel opening with the top of the pipe within the body panel opening.
3. Install the fuel filler hose onto the fuel tank inlet.
4. Install the fuel filler pipe intermediate bracket bolt. Do not tighten at this time.
5. Lower the vehicle and install the filler pipe to upper fuel fill pipe support bracket by moving the fuel filler neck up and to the right, toward the front of the vehicle. Tighten the fuel fill pipe-to-body bolt. Tighten: Tighten the bolt to 3 N.m (27 lb in).
6. Install the fuel cap.
7. Raise the vehicle to a comfortable working height.
8. Tighten the hose clamp on the filler pipe-to-fuel tank connecting hose. Tighten: Tighten the fuel fill neck-to-fuel tank clamp to 5 N.m (44 lb in).
9. Connect the fuel fill pipe vent tube and fresh air hose.
10. Tighten the intermediate bracket bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
11. Install the inner wheelhouse liner. Refer to Wheelhouse Liner Panel Replacement - Rear in Body Front End.
12. Install the wheel and tire. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
14. Lower the vehicle from the hoist.
15. Perform the Service Bay Diagnostic Test for the EVAP emission system using the scan tool. This test will verify the integrity of the vapor handling areas of the fuel system.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
2. Disconnect the negative battery terminal. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
3. From underhood, remove the fuel line clip and using the Snap-On™ tool YA 9457 or equivalent, disconnect the fuel feed line from the fuel rail.
4. Disconnect the evaporative emission (EVAP) purge line from the EVAP purge solenoid.
5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
6. Disconnect the chassis fuel feed line from the fuel tank.
7. Disconnect the EVAP purge line from the EVAP canister.
8. Release the fuel and EVAP purge lines from underbody retainers.

1. Make sure the lines are not kinked, bent, or damaged.
2. Install the fuel and EVAP lines into underbody retainers. Make sure the lines are properly routed and attach retainers to the vehicle.
3. Connect the EVAP purge line onto the EVAP canister.
4. Lower the vehicle from the hoist.
5. Connect the fuel feed line to fuel rail and install the safety clip.
6. Connect the negative battery terminal. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
7. Prime the fuel system. Cycle the ignition ON for 5 seconds and then OFF for 10 seconds. Repeat step 7.1 twice. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds. If the engine does not start, repeat steps 7.1-7.4.
8. Run the engine and check the system for leaks.

1. Turn ignition OFF.
2. Disconnect both purge link quick connects from the evaporative emission (EVAP) purge solenoid.
3. Disconnect the EVAP purge solenoid harness connector.
4. Slide the EVAP purge solenoid from the retaining bracket.

1. Slide the EVAP purge solenoid into the retaining bracket.
2. Connect the purge line quick connects to the EVAP purge solenoid. Push in the connector until a slick is heard, then pull back to confirm positive engagement.
3. Connect the EVAP purge solenoid harness connector.

1. Raise the vehicle on a hoist.
2. Remove the 3 EVAP canister-to-underbody fasteners and slightly lower the EVAP canister enough to remove the EVAP vent solenoid.
3. Disconnect the EVAP vent solenoid electrical connector.
4. Turn the EVAP vent solenoid counter clockwise and remove from the EVAP canister.

1. Install the EVAP vent solenoid by gently turning the solenoid clockwise until it clicks into position.
2. Connect the EVAP vent solenoid electrical connector.
3. Install the EVAP canister bracket-to-underbody fasteners. Tighten: Tighten the EVAP canister-to-body nuts to 8 N.m (71 lb in).
4. Lower the vehicle from the hoist.

1. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle in General Information.
2. Disconnect the EVAP canister fresh air line from the fuel tank fresh air line.
3. Disconnect the EVAP canister purge line and vent line from the EVAP canister.
4. Remove the EVAP canister-to-underbody fasteners.
5. Disconnect the EVAP vent solenoid electrical connector.
6. Remove the canister from the vehicle.

1. Connect the EVAP vent solenoid electrical connector.
2. Install the EVAP canister-to-body underbody fasteners. Tighten: Tighten the EVAP canister nuts to 8 N.m (71 lb in).
3. Connect the EVAP canister purge and vent lines to the EVAP canister.
4. Connect the EVAP canister fresh air line to the fuel tank fresh air line.
5. Lower the vehicle from the hoist.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle 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 .
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 .
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. Disconnect the intake air temperature (IAT) sensor connector.
2. Loosen the clamp at the air cleaner assembly.
3. Remove the push-push attachment from the outlet resonator/duct assembly to support bracket.
4. Loosen the clamp at the throttle body assembly.
5. Disconnect the PCV fresh air bent hose at the cam cover.
6. Remove the outlet resonator/duct assembly.
7. Disconnect the EI module electrical connector.
8. If the module only is being replaced, remove the EI module attachment screws.
9. Remove the ignition module attachment bolts.
10. Remove the ignition module housing assembly with spark plug boots.

1. Apply dialectic compound to the spark plug boots and ensure no corrosion is present.
2. Install the ignition module housing assembly with spark plug boots into position. Tighten: Tighten the ignition module-to-camshaft cover bolts to 10 N.m (89 lb in).
3. Install the EI module and attachment screws (if removed). Tighten: Tighten the module screws to 1.5 N.m (13 lb in).
4. Connect the EI module harness connector. Push in the connector until a slick is heard, then pull back to confirm a positive engagement.
5. Position the outlet resonator/duct assembly into position.
6. Connect the PCV fresh air bent hose assembly.
7. Tighten the clamp at the throttle body assembly.
8. Position the outlet resonator/duct assembly up with the support bracket and install the push-pin.
9. Tighten the clamp at the air cleaner assembly.
10. Connect the intake air temperature (IAT) sensor connector.

1. Disconnect the intake air temperature (IAT) sensor connector.
2. Loosen the clamp at the air cleaner assembly.
3. Remove the push-pin attachment from the outlet resonator/duct assembly to support bracket.
4. Loosen the clamp at the throttle body assembly.
5. Disconnect the PCV fresh air bent hose at the cam cover.
6. Remove the outlet resonator/duct assembly.
7. Disconnect the EI module electrical connector.
8. Remove the ignition module attachment bolts.
9. Remove the ignition module housing assembly with the spark plug boots from the spark plugs.
10. Remove the spark plugs using a spark plug socket.

1. Gap the spark plugs. Specification: Spark Plug Gap: 1.14 mm
2. Install the spark plugs. Tighten: Tighten the spark plugs to 20 N.m (15 lb ft).
3. Apply dielectric compound to the spark plug boots and ensure no corrosion is present.
4. Install the ignition module housing assembly with spark plug boots into position. Tighten: Tighten the ignition module-to-camshaft cover bolts to 10 N.m (89 lb in).
5. Connect the EI module harness connector. Push in until a click is heard and pull back to confirm a positive engagement.
6. Position the outlet resonator/duct assembly into position.
7. Connect the PCV fresh air vent hose assembly.
8. Tighten the clamp at the throttle body assembly.
9. Position the outlet resonator/duct assembly up with support bracket and install the push-pin.
10. Tighten the clamp at the air cleaner assembly.
11. Connect the intake air temperature (IAT) sensor connector.

1. Remove the starter. Refer to Starter Motor Replacement (L61) or Starter Motor Replacement (L66) 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 (L61) or Starter Motor Replacement (L66) in Engine Electrical.
6. Perform the CKP system Variation Learn Procedure. Refer to CKP System Variation Learn Procedure .

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
2. Remove the knock sensor harness connector.
3. Remove the knock sensor connector from the retaining clip by inserting a flat-bladed screwdriver between the connector and clip while sliding the connector upward.
4. Remove the knock sensor.

1. Insert the knock sensor pigtail connector with retaining clip into the intake manifold hole or slide the knock sensor pigtail connector over the retaining clip from the top.
2. Connect the knock sensor harness connector. Push in the connector until a click is heard, then pull back to confirm a positive engagement.
3. Install the knock sensor at the 9 o'clock position and attachment bolt. Tighten: Tighten the knock-sensor-engine block bolt to 25 N.m (18 lb ft).
4. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.

1. Loosen the clamp at the air cleaner assembly.
2. Unclamp the air cleaner lid
3. Remove the air filter assembly.

1. Install the air filter into the box.
2. Install the air cleaner lid and snap clips onto the lid.
3. Connect the outlet resonator duct assembly to the air cleaner lid. Tighten the clamp. Tighten: Tighten the outlet resonator clamps to 4 N.m (36 lb in).
4. Connect the intake air temperature (IAT) sensor connector.

1. Disconnect the intake air temperature (IAT) sensor connector.
2. Loosen the clamp at the air cleaner assembly.
3. Remove the outlet resonator duct from the air cleaner.
4. Loosen the clamp at throttle body assembly.
5. Disconnect PCV fresh air vent hose at cam cover.
6. Remove the air outlet resonator/bolt.
7. Remove the air cleaner attachment bolt.
8. Remove the air cleaner assembly.

1. Install the air cleaner assembly into position.
2. Install the air cleaner attachment bolt. Tighten: Tighten the air cleaner-to-support bracket bolt 4 cylinder to 10 N.m (89 lb in).
3. Position the outlet resonator/duct assembly.
4. Connect the PCV fresh air vent hose assembly.
5. Tighten the clamp at throttle body assembly.
6. Position outlet resonator/duct assembly up with support bracket and install push-pin.
7. Tighten the clamp at the air cleaner assembly.
8. Connect the intake air temperature (IAT) sensor connector.

1. Disconnect the intake air temperature (IAT) sensor connector
2. Loosen the clamp at the air cleaner assembly.
3. Remove the push pin attachment from the outlet resonator/duct assembly to support bracket.
4. Loosen the clamp at throttle body assembly.
5. Disconnect the PCV fresh air vent hose at cam cover.
6. Remove the outlet resonator/duct assembly.

1. Install the outlet resonator/duct assembly into position at the throttle body and air cleaner.
2. Connect the PCV fresh air vent hose assembly.
3. Tighten the clamp at the throttle body assembly.
4. Position the outlet resonator/duct assembly up with the support bracket and install the push-pin.
5. Tighten the clamp at the air cleaner assembly.
6. Connect the intake air temperature (IAT) sensor connector.

1. Remove the front fascia. Refer to Fascia Replacement - Front Bumper in Bumpers.
2. Remove the inlet duct assembly attachment bolts.
3. Remove the inlet duct assembly.

1. Install the air resonator/duct assembly.
2. Install the air resonator/duct assembly bolts. Tighten: Tighten the air resonator/duct assembly-to-body to 10 N.m (89 lb in).
3. Install the front fascia. Refer to Fascia Replacement - Front Bumper in Bumpers.