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Engine Controls (Introduction) -- 3.5L (L66): Removal & Installation Saturn VUE I

Testing & Diagnostics 1 illustration ~6411 words

Removal Procedure

  1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-188769-S19455074222005090200000) in Engine Electrical.
  2. Disconnect the wiring harness.
  3. Depress the retaining tab and remove the powertrain control module (PCM).
  4. Remove the PCM from the housing.

Installation Procedure

  1. Install the PCM into the housing bracket.
  2. Connect the wiring harness.
  3. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-188769-S19455074222005090200000) in Engine Electrical.
  4. Program the PCM. Refer to «Service Programming System (SPS)»(ref-188776-S20930138392005090200000) in Programming.
  5. Perform the Idle Learn procedure. Refer to «Idle Learn Procedure»(ref-188786-S26252071172005090200000) .
  1. Remove the positive crankcase ventilation (PCV) valve bolt.
  2. Remove the PCV valve.
  1. Install the PCV valve.
  2. Install the PCV bolt. Tighten: Tighten the bolt to 12 N.m (106 lb in).
  1. Turn ignition OFF.
  2. Disconnect the ECT sensor harness connector.
  3. Remove the ECT.
  1. Apply thread sealant SA P/N 21485277 Loctite 242® Threadlocker (or equivalent) to sensor threads.
  2. Install the ECT sensor with a new O-ring. Tighten: Tighten the engine coolant temperature sensor to 18 N.m (13 lb ft).
  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»(ref-188798-S18526938392005090200000) 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 cleaner housing.
  1. Install the IAT sensor with a new O-ring.
  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. Turn the ignition OFF.
  2. Disconnect the IAT sensor harness connector.
  3. Remove the IAT sensor from the side of the intake manifold (5).
  1. Install the IAT sensor to the side of the intake manifold (5). Tighten: Tighten the IAT sensor to 18 N.m (13 lb ft).
  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. Turn the ignition OFF.
  2. Disconnect the manifold absolute pressure (MAP) sensor harness connector.
  3. Remove the MAP sensor attachment screw and remove the MAP sensor and O-ring (6).
  1. Make sure the MAP sensor mounting surface is clean. Install the MAP sensor with the new O-ring and attachment bolt (6). Tighten: Tighten the manifold absolute pressure sensor screw to 4 N.m (35 lb in).
  2. Connect the MAP sensor harness connector. Push the connector in until the lock position is felt, then pull back to confirm engagement.
  1. Turn the ignition OFF.
  2. Disconnect the bank 1 heated oxygen sensor 1 harness connector (1).
  3. Remove the oxygen sensor using the J 39194-C .
  1. Apply a small amount of the anti-seize compound SA P/N 21485279, or equivalent, to the threads of the heated oxygen sensor 1.
  2. Install the heated oxygen sensor 1 using the J 39194-C . Tighten: Tighten the oxygen sensor to 44 N.m (33 lb ft).
  3. Connect the bank 1 heated oxygen sensor 1 harness connector (1). Make sure the locking tab is in the full closed position.
  4. Start the engine and make sure no exhaust leaks exist.
  1. Turn the ignition OFF.
  2. Disconnect the bank 1 heated oxygen sensor 2 harness connector (2).
  3. Disconnect the connectors from the retaining bracket.
  4. Remove the heated oxygen sensor connector retaining bracket and bolt.
  5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
  6. Remove the heated oxygen sensor wiring harness bracket and bolt.
  7. Remove the bank 1 heated oxygen sensor 2 using the J 39194-C .
  1. Apply a small amount of anti-seize compound SA P/N 21485279, or equivalent, to the threads of the heated sensor 2.
  2. Install the bank 1 heated oxygen sensor 2 using the J 39194-C . Tighten: Tighten the oxygen sensor to 44 N.m (33 lb ft).
  3. Install the heated oxygen sensor wiring harness bracket and bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  4. Lower the vehicle.
  5. Install the heated oxygen sensor connector retaining bracket and bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  6. Connect the bank 1 heated oxygen sensor 2 harness connector (2). Make sure the locking tab is in the full closed position.
  7. Connect the connectors to the retaining bracket.
  8. Start the engine and make sure no exhaust leaks exist.
  1. Turn the ignition OFF.
  2. Disconnect the bank 2 heated oxygen sensor 1 harness connector (1).
  3. Remove the bank 2 heated oxygen sensor 1 using the J 39194-C .
  1. Apply a small amount of the anti-seize compound SA P/N 21485279, or equivalent, to the threads of the heated oxygen sensor.
  2. Install the bank 2 heated oxygen sensor 1 using the J 39194-C . Tighten: Tighten the oxygen sensors (exhaust manifold) to 44 N.m (33 lb ft).
  3. Connect the heated oxygen sensor harness connector (1). Make sure the locking tab is in the full closed position.
  4. Start the engine and make sure no exhaust leaks exist.
  1. Turn the ignition OFF.
  2. Disconnect the bank 2 heated oxygen sensor 2 harness connector (2) and disconnect from the retaining bracket.
  3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
  4. Remove the left transmission mount just enough to gain access to the heated oxygen sensor. Refer to «Automatic Transmission Mount Replacement - Rear»(ref-188853-S41521518782005090200000) in Automatic Transmission.
  5. Remove the heated oxygen sensor wiring harness bracket and bolt.
  6. Remove the bank 2 heated oxygen sensor 2 using the J 39194-C .
  1. Apply a small amount of the anti-seize compound SA P/N 21485279, or equivalent, to the threads of the heated oxygen sensor.
  2. Install the bank 2 heated oxygen sensor 2 using the J 39194-C . Tighten: Tighten the oxygen sensors (exhaust manifold) to 44 N.m (33 lb ft).
  3. Install the heated oxygen sensor wiring harness bracket and bolt. Tighten: Tighten the bolt to 40 N.m (30 lb ft).
  4. Install the left transmission mount. Refer to «Automatic Transmission Mount Replacement - Rear»(ref-188853-S41521518782005090200000) in Automatic Transmission.
  5. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
  6. Connect the heated oxygen sensor harness connector (2). Make sure the locking tab is in the full closed position.
  7. Start the engine and make sure no exhaust leaks exist.
  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. Remove the outlet resonator/duct assembly. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) .
  2. Cover the throttle body opening with a shop towel and use shop air to remove any dirt at the base of the throttle body.
  3. Disconnect the MAP sensor connector.
  4. Disconnect the throttle control connector at throttle body.
  5. Clamp off the hoses to avoid leaking coolant on engine.
  6. Remove the wiring harness bracket bolt from the throttle body.
  7. Remove the coolant hoses at throttle body (4).
  8. Remove the throttle body fasteners.
  9. Remove the throttle body.
  10. 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 a new throttle body gasket.
  3. Install the throttle body assembly and fasteners.
  4. Install the throttle body fasteners. Tighten: Tighten the fasteners to 22 N.m (16 lb in).
  5. Attach the coolant hoses (4) to the throttle body assembly and unclamp.
  6. Install the wiring harness bracket bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  7. Connect the MAP sensor connectors.
  8. Connect throttle body electrical connector.
  9. Install the outlet resonator/duct assembly into position. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) .
  10. If the throttle body assembly has been replaced, perform the idle learn procedure. Refer to «Idle Learn Procedure»(ref-188786-S26252071172005090200000) .
  1. Remove the intake air duct with resonator from the engine. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) .
  2. Connect one end of the gage hose (1) from the SA9127E , to the fuel shut off and bleed assembly (5).
  3. Connect the other end of the gage hose (1) to the fuel pressure gage side of the gage bar set (2).
  4. Remove the schrader valve cap.
  5. Connect the fuel shut off and bleed assembly (5) to the schrader valve on the fuel feed pipe (4) near the fuel rail. Use a shop towel in order to catch any remaining fuel that may leak.
  6. Use the scan tool, in order to pressurize the fuel system. Refer to «Scan Tool Output Controls»(ref-188783-S04773074012005090200000) .
  7. Use the drain hose (3) of the fuel shut off and bleed assembly (5) to bleed any trapped air from the lines and hoses.
  8. After bleeding the lines and hoses, pressurize the fuel system.
  9. Inspect for any fuel leaks.
  1. Start the engine and command the fuel pump OFF with the scan tool. Refer to «Scan Tool Output Controls»(ref-188783-S04773074012005090200000) .
  2. Run the engine until the engine stalls.
  3. Use the drain hose (3) of the fuel shut off and bleed assembly (5) in order to drain any remaining fuel from the gage, the lines, and the hoses.
  4. Disconnect the gage hose (1) from the fuel shut off and bleed assembly (5).
  5. Remove the fuel shut off and bleed assembly (5) from the fuel feed pipe (4). Use a shop towel in order to catch any remaining fuel that may leak.
  6. Install the schrader valve cap in order to protect the fitting from dirt and contaminants.
  7. Install the intake air duct to the engine. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) .
  8. Perform the idle learn procedure. Refer to «Idle Learn Procedure»(ref-188786-S26252071172005090200000) .
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-188785-S01720955142005090200000) .
  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. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-188785-S01720955142005090200000) .
  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.
CAUTIONIn order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.
  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. 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. Blow dirt out of the fitting using compressed air.
  2. Depress the retaining tab (2) while holding the connector housing (1).
  3. Continue to depress the retaining tab 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. 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»(ref-188786-S10066296552005090200000) .
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-188786-S07925041012005090200000) .
  3. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-188769-S19455074222005090200000) in Engine Electrical.
  4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) 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»(ref-188830-S08632284852005090200000) in Propeller Shaft.
  7. Disconnect the 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»(ref-188786-S27452618432005090200000) and «Fuel Tank Module Replacement - Secondary»(ref-188786-S41029793682005090200000) .
  1. Install the fuel tank module assemblies. Refer to «Fuel Tank Module Replacement - Primary»(ref-188786-S27452618432005090200000) and «Fuel Tank Module Replacement - Secondary»(ref-188786-S41029793682005090200000) .
  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»(ref-188830-S08632284852005090200000) 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»(ref-188769-S19455074222005090200000) 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»(ref-188786-S18407650372005090200000) .
  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-188786-S18407650372005090200000) .
  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»(ref-188786-S10066296552005090200000) .
  2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-188769-S19455074222005090200000) 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»(ref-188813-S15240900572005090200000) in General Information.
  6. Remove the right rear wheel and tire. Refer to «Tire and Wheel Removal and Installation»(ref-188815-S07973846162005090200000) in Tires and Wheels.
  7. Remove the right rear wheelhouse inner liner. Refer to «Wheelhouse Liner Panel Replacement - Rear»(ref-188807-S02556423852005090200000) 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.
  6. Tighten the fuel fill pipe-to-body bolt. Tighten: Tighten the bolt to 3 N.m (27 lb in).
  7. Install the fuel cap.
  8. Raise the vehicle to a comfortable working height.
  9. 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).
  10. Connect the fuel fill pipe vent tube and fresh air hose.
  11. Tighten the intermediate bracket bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  12. Install the inner wheelhouse liner. Refer to «Wheelhouse Liner Panel Replacement - Rear»(ref-188807-S02556423852005090200000) in Body Front End.
  13. Install the wheel and tire. Refer to «Tire and Wheel Removal and Installation»(ref-188815-S07973846162005090200000) in Tires and Wheels.
  14. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-188769-S19455074222005090200000) in Engine Electrical.
  15. Lower the vehicle from the hoist.
  16. 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. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-188786-S18407650372005090200000) .
  2. Remove the secondary fuel pump module. Refer to «Fuel Tank Module Replacement - Secondary»(ref-188786-S41029793682005090200000) .
  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.
  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»(ref-188786-S26138361362005090200000) .
  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»(ref-188786-S26138361362005090200000) .
  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.
  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»(ref-188786-S41029793682005090200000) .
  6. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-188786-S18407650372005090200000) .
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-188786-S18407650372005090200000) .
  2. Disconnect the EVAP vent line quick connect.
  3. Use the SA9156E and remove the fuel pump module retaining ring.
  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 not being replaced as well, remove the fuel level sender. Refer to «Fuel Level Sensor Replacement - Secondary»(ref-188786-S15983623802005090200000) .
  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»(ref-188786-S15983623802005090200000) .
  2. Connect the suction port.
  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.
  5. Connect the EVAP line quick connect.
  6. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-188786-S18407650372005090200000) .
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-188786-S18407650372005090200000) .
  2. Remove the fuel pump module. Refer to «Fuel Tank Module Replacement - Primary»(ref-188786-S27452618432005090200000) .
  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»(ref-188786-S27452618432005090200000) .
  4. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-188786-S18407650372005090200000) .
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-188786-S18407650372005090200000) .
  2. Remove the fuel pump module. Refer to «Fuel Tank Module Replacement - Secondary»(ref-188786-S41029793682005090200000) .
  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»(ref-188786-S41029793682005090200000) .
  4. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-188786-S18407650372005090200000) .
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-188786-S07925041012005090200000) .
  2. Disconnect the negative battery terminal. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-188769-S19455074222005090200000) 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»(ref-188813-S15240900572005090200000) 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»(ref-188769-S19455074222005090200000) 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. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-188786-S07925041012005090200000) .
  2. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-188818-S06890148622005090200000) in Engine Mechanical.
  3. Disconnect the fuel injector electrical connectors.
  4. Remove the bolts.
  5. Remove the fuel rail and injectors from the manifold as an assembly.
  1. Install new O-rings to the injectors.
  2. Install the fuel rail and injectors as an assembly to the manifold.
  3. Install the bolts. Tighten: Tighten the bolts to 9.8 N.m (87 lb in).
  4. Connect the fuel injector electrical connectors.
  5. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-188818-S06890148622005090200000) in Engine Mechanical.
  6. Inspect for fuel leaks using the following procedure: With the engine OFF, turn ON the ignition for 2 seconds. Inspect for fuel leaks. Turn the ignition OFF for at least 10 seconds. With the engine OFF, turn ON the ignition for 2 seconds. Inspect for fuel leaks. Turn the ignition OFF.
  1. Remove the fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-188786-S31979179522005090200000) .
  2. Remove the fuel injectors from the fuel rail.
  3. Remove and discard the fuel injector O-rings.
  1. Install the O-rings on the fuel injector (1).
  2. Install the fuel injector in the fuel rail with the connector facing upward.
  3. Install the fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-188786-S31979179522005090200000) .
  1. Disconnect the evaporative emission (EVAP) canister purge valve harness connector (1).
  2. Disconnect the vacuum pipe (2) from the EVAP canister purge valve.
  3. Disconnect the purge pipe (3) 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-188786-S09604176732005090200000) .
  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 (2) to the EVAP canister purge valve.
  4. Connect the vacuum pipe (3) to the EVAP canister purge valve.
  5. Connect the EVAP canister purge valve harness connector (1).
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
  2. Remove the EVAP canister bolts.
  3. Disconnect the electrical connector from the evaporative emission EVAP canister vent solenoid valve.
  4. Disconnect the EVAP canister lines.
  5. Remove the EVAP canister from the vehicle.
  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. Connect the electrical connector to the EVAP canister vent valve.
  4. Connect the EVAP lines.
  5. Install the EVAP canister and bolts. Tighten: Tighten the bolts to 8 N.m (71 lb in).
  6. Lower the vehicle.
  1. Disconnect the EVAP purge pipe from the engine purge hose. Refer to «Quick Connect Fitting(s) Service (Plastic Collar) (Plastic Collar)»(ref-188786-S11724764142005090200000) or «Quick Connect Fitting(s) Service (Plastic Collar) (Plastic Collar Press Release)»(ref-188786-S36558302372005090200000) or «Quick Connect Fitting(s) Service (Plastic Collar) (Plastic Collar Lever Release)»(ref-188786-S02491453342005090200000) .
  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-188813-S15240900572005090200000) in General Information.
  4. Disconnect the EVAP pipe from the EVAP canister.
  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. Connect the EVAP pipe to the EVAP canister.
  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) (Plastic Collar)»(ref-188786-S11724764142005090200000) or «Quick Connect Fitting(s) Service (Plastic Collar) (Plastic Collar Press Release)»(ref-188786-S36558302372005090200000) or «Quick Connect Fitting(s) Service (Plastic Collar) (Plastic Collar Lever Release)»(ref-188786-S02491453342005090200000) .
  1. Raise the vehicle on a hoist. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) 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»(ref-188813-S15240900572005090200000) 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 air cleaner outlet duct assembly. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) .
  2. Disconnect the electrical connectors.
  3. Remove the engine coil bolts.
  4. Remove the engine coils.
  1. Install the engine coils.
  2. Install the engine coil bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
  3. Connect the electrical connectors.
  4. Install the air cleaner outlet duct assembly. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) .
  1. Disconnect the electrical connectors.
  2. Remove the engine coil bolts.
  3. Remove the engine coils.
  1. Install the engine coils.
  2. Install the engine coil bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
  3. Connect the electrical connectors.

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 coils. Refer to «Ignition Coil(s) Replacement - Bank 1»(ref-188786-S39476477052005090200000) and «Ignition Coil(s) Replacement - Bank 2»(ref-188786-S06347744432005090200000) .
  2. Remove the spark plugs with a spark plug socket.
  3. Inspect the spark plugs. Refer to «Spark Plug Inspection»(ref-188786-S37999952392005090200000) .
  1. Gap the spark plug, using round wire type spark plug gap gage. Gap: Adjust the spark plug gap to 1.1 mm (0.043 in).
  2. Install the spark plugs with a spark plug socket. Tighten: Tighten the spark plugs to 18 N.m (13 lb in).
  3. Install the ignition coils. Refer to «Ignition Coil(s) Replacement - Bank 1»(ref-188786-S39476477052005090200000) and «Ignition Coil(s) Replacement - Bank 2»(ref-188786-S06347744432005090200000) .
  1. Remove the engine front cover. Refer to «Timing Belt Cover Replacement»(ref-188818-S24076870982005090200000) in Engine Mechanical - 3.5L.
  2. Remove the timing belt guide (703).
  3. Remove the crank sensor and harness.
  1. Install the crank sensor and harness.
  2. Install the timing belt guide (703). Tighten: Tighten the timing belt fasteners to 10 N.m (88 lb in).
  3. Install the front cover. Refer to «Timing Belt Cover Replacement»(ref-188818-S24076870982005090200000) in Engine Mechanical - 3.5L.
  4. Perform the idle learn procedure. Refer to «Idle Learn Procedure»(ref-188786-S26252071172005090200000) in Engine Controls - 3.5L (L66).
  1. Remove the left camshaft sprocket. Refer to «Camshaft Drive Sprocket Replacement - Left»(ref-188818-S41543237672005090200000) in Engine Mechanical - 3.5L (L66).
  2. Remove the bolt (240), sprocket (241), bolts (242), cover (244) and seal (243).
  3. Remove the bolt (723) and camshaft position (CMP) sensor (700).
  1. Install the camshaft position (CMP) sensor (700) and bolt (723). Tighten: Tighten the bolt to 4 N.m (35 lb in).
  2. Install the cover (244), NEW seal (243) and bolts (242). Tighten: Tighten the bolts to 22 N.m (16 lb ft).
  3. Install the left camshaft sprocket. Refer to «Camshaft Drive Sprocket Replacement - Left»(ref-188818-S41543237672005090200000) in Engine Mechanical - 3.5L (L66).
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
  2. Remove the right front wheel. Refer to «Tire and Wheel Removal and Installation»(ref-188815-S07973846162005090200000) in Tires and Wheels.
  3. Remove the splash shield. Refer to «Splash Shield Replacement - Engine»(ref-188792-S35668225222005090200000) in Body Front End.
  4. Remove the solenoid and bolts.
  5. Discard the O-ring.
  1. Install the NEW O-ring (415), solenoid (416) and bolts (417). Tighten: Tighten the switch to 12 N.m (106 lb in).
  2. Install the splash shield. Refer to «Splash Shield Replacement - Engine»(ref-188792-S35668225222005090200000) in Body Front End.
  3. Install the wheel. Refer to «Tire and Wheel Removal and Installation»(ref-188815-S07973846162005090200000) in Tires and Wheels.
  4. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
  2. Remove the right front wheel. Refer to «Tire and Wheel Removal and Installation»(ref-188815-S07973846162005090200000) in Tires and Wheels.
  3. Remove the splash shield. Refer to «Splash Shield Replacement - Engine»(ref-188792-S35668225222005090200000) in Body Front End.
  4. Remove the switch and O-ring.
  5. Discard the O-ring.
  1. Install the NEW O-ring and switch. Tighten: Tighten the switch to 22 N.m (16 lb ft).
  2. Install the splash shield. Refer to «Splash Shield Replacement - Engine»(ref-188792-S35668225222005090200000) in Body Front End.
  3. Install the wheel. Refer to «Tire and Wheel Removal and Installation»(ref-188815-S07973846162005090200000) in Tires and Wheels.
  4. Lower the vehicle.
  1. Remove the lower left intake manifold. Refer to «Intake Manifold Spacer Replacement»(ref-188818-S19966657682005090200000) and «Intake Manifold Replacement - Lower Left»(ref-188818-S25789479212005090200000) in Engine Mechanical - 3.5L (L66).
  2. Disconnect the wiring harness connector from the knock sensor (KS).
  3. Remove the KS from the engine block.

Note. Refer to Fastener Notice in Cautions and Notices.

IMPORTANTDO NOT apply thread sealant to the sensor threads. The sensor threads are coated at the factory and applying additional sealant affects the sensors ability to detect detonation.
  1. Install the KS into engine block. Tighten: Tighten the KS to 31 N.m (23 lb ft).
  2. Connect the KS wiring harness connector to the knock sensor.
  3. Install the lower left intake manifold. Refer to «Intake Manifold Spacer Replacement»(ref-188818-S19966657682005090200000) and «Intake Manifold Replacement - Lower Left»(ref-188818-S25789479212005090200000) in Engine Mechanical - 3.5L (L66).
  1. Turn OFF the ignition.
  2. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
  3. Remove the EGR valve retaining nuts.
  4. Remove the EGR valve assembly.
  5. Remove the gasket.
  6. Clean the EGR valve mating surface.
  1. Install the EGR valve with a new gasket to the engine.
  2. Install the EGR valve nuts. Tighten: Tighten the nuts to 22 N.m (16 lb ft).
  3. Connect the EGR valve electrical connector.
  1. Loosen the clamp at the air cleaner assembly.
  2. Remove the outlet resonator/duct assembly from the air cleaner. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) .
  3. Release the clamps on the side of the air cleaner assembly.
  4. Remove the upper air cleaner lid.
  5. Remove the air filter assembly.
  1. Install the air filter assembly.
  2. Install the air cleaner assembly lid into position.
  3. Fasten the clips into position inside of the air cleaner.
  4. Install the outlet resonator/duct assembly into position. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) .
  5. Tighten the clamp at the air cleaner assembly. Tighten: Tighten the clamp to 4 N.m (35 lb in).
  1. Loosen the clamp at the air cleaner assembly.
  2. Disconnect the IAT 1 sensor connector.
  3. Remove the air cleaner assembly top cover and filter element.
  4. Remove the air cleaner assembly bolt.
  5. Remove the air cleaner assembly.
  1. Install the air cleaner assembly into position, aligning locking pins into the front panel.
  2. Install the air cleaner attachment bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  3. Install the filter element and air cleaner assembly top cover.
  4. Tighten the clamp at the air cleaner assembly. Tighten: Tighten the clamp to 4 N.m (35 lb in).
  5. Connect the IAT 1sensor connector.
  1. Remove the front fascia. Refer to «Fascia Replacement - Front Bumper»(ref-188808-S27906573402005090200000) in Bumpers.
  2. Remove the inlet duct assembly attachment bolts (1).
  3. Remove the inlet duct assembly (2).
  1. Install the inlet duct assembly.
  2. Install the inlet duct assembly bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  3. Install the front fascia. Refer to «Fascia Replacement - Front Bumper»(ref-188808-S27906573402005090200000) in Bumpers.
  1. Loosen clamp at the air cleaner assembly and the front outlet duct seal assembly.
  2. Remove the attachment bolt from the support bracket.
  3. Remove the outlet resonator/duct assembly.
  1. Install the outlet resonator/duct assembly into position.
  2. Position the outlet resonator/duct assembly to support bracket and install the bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  3. Tighten the clamps at the air cleaner assembly and the front outlet duct seal assembly. Tighten: Tighten the clamps to 4 N.m (35 lb in).

Scheme 86

Scheme 86: Powertrain Control Module (PCM) Description
Scheme 86: Powertrain Control Module (PCM) Description

The powertrain control module (PCM) is a precision 32-bit microprocessor and is an essential part of the electronic control system. The PCM is located underhood on the right side of the engine compartment. The PCM uses a KW2000 communication protocol. Communication with the PCM is through the data link connector located on the left side of the passenger compartment below the IP.

The PCM performs the OBD II diagnostic tests of the emission related systems. The PCM supplies a buffered voltage, called reference voltage, to the various information sensors and switches. The PCM controls most components with an electronic switch that completes a ground circuit when turned ON. The electronic switch is commonly referred to as an output driver. The PCM is also responsible for a self-diagnosis function and a fail-safe function.

Self-Diagnosis Function

The powertrain control module (PCM) diagnoses any troubles which may occur in the engine control system when the ignition switch is in the ON position with the engine running. The PCM indicates a malfunction by illuminating the malfunction indicator lamp (MIL) when a fault occurs in any of the following systems

  1. The heated oxygen sensor 1 (HO2S 1)
  2. The heated oxygen sensor 2 (HO2S 2)
  3. The engine coolant temperature (ECT) sensor
  4. The accelerator pedal position (APP) sensors
  5. The intake air temperature (IAT) sensors
  6. The camshaft position (CMP) sensor
  7. The crankshaft position (CKP) sensors
  8. The knock sensor (KS) system
  9. The evaporative emission (EVAP) control system
  10. The throttle actuator control (TAC) system
  11. The rocker arm oil control system
  12. The vehicle speed sensor (VSS)
  13. The misfire detection
  14. The fuel-trim
  15. The catalyst monitor
  16. The central processing unit (CPU) of the PCM

When the PCM detects a malfunction in one of the above areas, the PCM will illuminate or flash the MIL in order to notify the driver of the occurrence of a fault.

More articles — Engine Controls (Introduction) -- 3.5L (L66)