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‌ENGINE PERFORMANCE

Engine Controls and Fuel - 1.5L (L3A) - Repair Instructions - Volt

REPAIR INSTRUCTIONS

WIRE TO WIRE REPAIR - ENGINE CONTROLS AND FUEL

Special Tools

EL-38125-10 Splice Sleeve Crimping Tool (non GMNA)

J-38125-5A Ultra Torch Special Tool

J-38125-8 Splice Sleeve Crimping Tool (GMNA)

For equivalent regional tools, refer to Special Tools .

WARNING: In order to reduce the risk of personal injury, loss of high voltage isolation to ground and higher system impedance, do not attempt to repair any HV wiring, connector, or terminal that is damaged. High voltage coaxial type cables are not repairable. Never attempt to repair a coaxial type cable. The entire cable/harness or component must be replaced. In order to maintain system integrity and personal safety, never attempt to repair any high voltage wiring, cables, or terminals. Performing this procedure on high voltage circuits may result in serious injury or death.

NOTE: If the wiring harness internal to the transmission is damaged, the wiring harness must be replaced. The use of splice sleeves in an attempt to repair the internal transmission wires, connectors, or terminals could result in performance issues.

NOTE: Do not splice wires in Door Harness Grommets.

NOTE: The DuraSeal splice sleeves have the following 2 critical features:

A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside.

A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits.

Use only DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except high voltage and specialty cables. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing.

Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves.

Splice Sleeve Selection

NOTE: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.

1. Open the harness by removing any tape:

Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage.

Use the DuraSeal splice sleeves on all types of insulation except Tefzel and coaxial.

Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together.

2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.

Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors.

3. Strip the insulation:

When adding a length of wire to the existing harness, use the same size wire as the original wire. Perform one of the following items in order to find the correct wire size:

Find the wire on the schematic and convert to regional wiring gauge size.

If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation.

Strip approximately 5.0 mm (0.20 in) of insulation from each wire to be spliced.

Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section.

4. For high temperature wiring, slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure.

5. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests.

Fig. 1: Splice Sleeve Crimping Tool With 4 Crimp Nests Courtesy of GENERAL MOTORS COMPANY

6. The EL-38125-10 splice sleeve crimping tool has four crimp nests. The largest crimp nest (4) is used for crimping 10 and 12 gauge wires. The second largest crimp nest (3) is used for crimping 14 and 16 gauge wires. The third largest crimp nest (2) is used for crimping 18 and 20 gauge wires. The smallest crimp nest (1) is used for crimping 22 to 26 gauge wires. The crimp nests are referenced in the table (farther above) under the crimp tool nest color.

Fig. 2: Splice Sleeve Crimping Tool With 3 Crimp Nests Courtesy of GENERAL MOTORS COMPANY

7. The J-38125-8 splice sleeve crimping tool has three crimp nests. The largest crimp nest (3) is used for crimping 10 and 12 gauge wires. The second largest crimp nest (2) is used for crimping 14 and 16 gauge wires. The smallest crimp nest (1) is used for crimping 18 to 20 gauge wires. The crimp nests are referenced in the table (farther above) under the crimp tool nest color.

8. Use the splice sleeve crimp tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. For the four crimp nest tool, use the three largest crimp nests to crimp the splice sleeves. For the three crimp nest tool, use all three crimp nests to crimp the splice sleeves. Use the four and three crimp tool diagrams (above) and the table (farther above) to match the splice sleeve with the correct crimp nest. The crimp tool diagram callout numbers match the numbers in the table (under crimp tool nest color).

Fig. 3: Identifying Duraseal Splice Sleeve Courtesy of GENERAL MOTORS COMPANY

9. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.

Fig. 4: Crimped Duraseal Splice Sleeve Courtesy of GENERAL MOTORS COMPANY

10. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. Refer to Folded-Over Wire Repair for splicing wires of 0.35 mm or less (22, 24, 26 gauge sizes) and for splicing wires of different gauges.

11. Tightly close the handles of the crimp tool until the crimper handles open when released.

The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 6 for the opposite end of the splice.

Fig. 5: Crimped Duraseal Splice Sleeve Courtesy of GENERAL MOTORS COMPANY

12. Using the heat torch, apply heat to the crimped area of the barrel.

13. Start in the middle and gradually move the heat barrel to the open ends of the tubing: The tubing will shrink completely as the heat is moved along the insulation.

A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.

Weatherpack™ Wiring Repair

NOTE: Some replacement pigtail connectors may be delivered without the terminated leads installed into the connector. For Weatherpack™ connectors, all terminated leads included in the package should to be installed into the connector. If the connector end view shows that a terminal is not occupied, the extra terminated lead(s) need to be installed and the end(s) sealed using a DuraSeal splice sleeve and taped back into the harness.

1. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. Refer to Folded-Over Wire Repair for splicing wires of 0.35 mm or less (22, 24, 26 gauge sizes) and for splicing wires of different gauges.

Fig. 6: Tightly Close Handles Of Crimp Tool Courtesy of GENERAL MOTORS COMPANY

2. Tightly close the handles of the crimp tool until the crimper handles open when released.

The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Holding the DuraSEAL with one hand gently tug on the wire to ensure it is crimped in the DuraSeal.

3. Using the heat torch, apply heat to the crimped area of the barrel.

Fig. 7: Heat To Crimped Area Of Barrel Courtesy of GENERAL MOTORS COMPANY

4. Start in the middle and gradually move the heat barrel to the open ends of the tubing: The tubing will shrink completely as the heat is moved along the insulation.

A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.

Fig. 8: Taping Extra Terminated Leads Back Into Harness Courtesy of GENERAL MOTORS COMPANY

5. Tape the extra terminated lead(s) back into the harness.

High Temperature Wiring Repairs

Use the following procedures to perform high temperature wiring repairs:

1. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve.

2. Using the heat torch, apply heat to the high temperature heat shrink tubing.

3. Gradually move the heat from the center to the open end of the tubing:

The tubing will shrink completely as the heat is moved along the insulation.

A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.

4. Replace any reflective tape and clips that may have been removed during the repair.

CONNECTOR RECONNECTION - ENGINE CONTROLS AND FUEL

Special Tools

EL-35616 Terminal Test Probe Kit

For equivalent regional tools, refer to Special Tools .

When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition.

Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items:

Loose, corroded, or painted terminal stud/fastener Wiring broken inside the insulation

Poor connection between the male and female terminal at a connector A terminal not seated all the way into the connector body

Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc.

Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits.

Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle.

Wiring that comes in contact with hot or exhaust components

Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern.

Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions.

Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation.

Testing for Terminal Fretting

Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface.

To correct a fretting condition disconnect the suspect connector and add dielectric grease / lubricant (Nyogel

760G or equivalent, meeting GM specification 9986087) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion.

Testing for Proper Terminal Contact

It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation.

Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.

Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the EL-35616 kit when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit.

Testing for Proper Terminal Contact in Bussed Electrical Centers

It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center. Use the EL-35616 kit to test for proper terminal contact. Failure to use the EL-35616 kit can result in improper diagnosis of the bussed electrical center.

Follow the procedure below in order to test terminal contact:

1. Separate the connector halves.

2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body.

3. Using an equivalent male terminal/terminated lead, verify that the retention force is significantly different between a known good terminal and the suspect terminal. Replace the female terminal in question.

Flat Wire Connectors

There are no serviceable parts for flat wire connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact:

1. Remove the component in question.

2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well.

3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation.

4. Insert the appropriate adapter into the flat wire harness connector in order to test the circuit in question.

Control Module/Component Voltage and Grounds

Poor voltage or ground connections can cause widely varying symptoms.

Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current.

Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing

, and Power Distribution Schematics .

Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested.

Inspect grounds for clean and tight connections at the grounding point (screw or stud). Inspect the connections at the component and in splice packs, where applicable. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing , and Ground Distribution Schematics .

Temperature Sensitivity

An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot.

Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable.

If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures

Underhood/engine generated heat

Circuit generated heat due to a poor connection, or high electrical load Higher than normal load conditions, towing, etc.

If the intermittent is related to cold, review the data for the following:

Low ambient temperatures - In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion.

The condition only occurs on a cold start.

The condition goes away when the vehicle warms up.

Information from the customer may help to determine if the trouble follows a pattern that is temperature related.

If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition.

Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required.

Electromagnetic Interference and Electrical Noise

Some electrical components/circuits are sensitive to electromagnetic interference or other types of electrical noise. Inspect for the following conditions:

A mis-routed harness that is too close to high voltage/high current devices such as secondary ignition

components, motors, generator etc. - These components may induce electrical noise on a circuit that could interfere with normal circuit operation.

Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch - These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating.

Installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc. - These accessories may create interference in other circuits while operating and the interference would disappear when the accessory is not operating. Refer to Checking Aftermarket Accessories .

Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode.

The generator may be allowing AC noise into the electrical system.

Incorrect Control Module

There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed.

A control module from another vehicle is installed.

Revised software/calibration files have been released for this vehicle.

NOTE: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern.

Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming.

BRAKE PEDAL POSITION SENSOR LEARN

Calibration Criteria

NOTE: Do not apply the brake pedal during the brake pedal position sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the brake pedal position sensor calibration must be repeated.

Brake pedal position sensor calibration must be performed after the brake pedal position sensor, body control module (BCM), or engine control module (ECM) have been serviced. The calibration procedure will set the brake pedal position sensor home value. This value is used by the BCM and ECM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data.

Calibration Procedure

1. Apply the parking brake.

2. Vehicle in Service Mode, transmission in Park.

3. Clear all DTCs.

4. Perform the scan tool Body Control Module Brake Pedal Position Sensor Learn procedure and follow the on-screen instructions.

5. Verify the scan tool Brake Pedal Position Sensor Learned Released Position parameter displays Yes when Learn is completed.

If Yes is not displayed

Repeat the procedure.

If Yes is displayed

6. Perform the scan tool Engine Control Module Brake Pedal Position Sensor Learn procedure and follow the on-screen instructions.

7. Verify the scan tool Brake Pedal Position Fully Released Position Learned parameter displays Yes when Learn is completed.

If Yes is not displayed

Repeat the procedure.

If Yes is displayed

8. All OK.

THROTTLE OR IDLE LEARN

Description

The engine control module (ECM) learns the airflow through the throttle body to ensure the correct engine speed. The learned airflow values are stored within the ECM. These values are learned to adjust for production variation and will continuously learn during the life of the vehicle to compensate for reduced airflow due to throttle body coking. Anytime the throttle body airflow rate changes, for example due to cleaning or replacing, the values must be relearned.

An engine that had a heavily coked throttle body that has been cleaned or replaced may take several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability to reset all learned values back to zero. A new ECM will also have values set to zero.

The engine speed may be unstable or a DTC may set if the learned values do not match the actual airflow.

Conditions for Running the Throttle Learn Procedure

Reset Procedure

DTCs P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0121, P0122, P0123, P0128, P0171, P0172, P0201, P0202, P0203, P0204, P0222, P0223, P0300, P0351, P0352, P0353, P0354, P0601, P0604, P0606, P060D, P0641, P0651, P0697, P06A3, P1101, P1516, P2101, P2119, P2122, P2123, P2127, P2128, P2135, P2138, or P2176 are not set.

Vehicle in Service Mode.

The vehicle speed sensor (VSS) is 0 km/h (0 mph).

Learn Procedure

DTCs P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0121, P0122, P0123, P0128, P0171, P0172, P0201, P0202, P0203, P0204, P0222, P0223, P0300, P0351, P0352, P0353, P0354, P0601, P0604, P0606, P060D, P0641, P0651, P0697, P06A3, P1101, P1516, P2101, P2119, P2122, P2123, P2127, P2128, P2135, P2138, or P2176 are not set.

The engine speed is between 1, 400 - 4, 000 RPM.

The manifold absolute pressure (MAP) is greater than 5 kPa. The mass air flow (MAF) is greater than 2 g/s.

The ignition voltage is greater than 10 V.

Throttle Learn

Reset Procedure - Performed after the throttle body is cleaned or replaced

1. Vehicle in Service Mode, perform the Idle Learn Reset with a scan tool.

2. Engine running, monitor the Throttle Body Idle Airflow Compensation parameter with a scan tool. The Throttle Body Idle Airflow Compensation value should equal 0 %.

3. Clear the DTCs and return to the diagnostic that referred you here.

Learn Procedure - Performed after the ECM is programmed or replaced

NOTE: Do NOT perform this procedure if DTCs are set. Refer to Diagnostic Trouble Code (DTC) List - Vehicle .

1. Engine running for 3 minutes.

2. Monitor the Engine Speed with a scan tool.

3. The ECM will start to learn the new idle cells and the Engine Speed should start to decrease.

4. Vehicle OFF for 60 s.

5. Engine running for 3 minutes.

6. After the 3 minute run time the engine speed should be normal.

7. Once the engine speed has returned to normal, clear DTCs and return to the diagnostic that referred you here.

METAL COLLAR QUICK CONNECT FITTING SERVICE

Special Tools

CH-41769 Fuel Line Disconnect Tool Set

CH-44581 Fuel Line Disconnect Tool

For equivalent regional tools, refer to Special Tools (Diagnostic Tools) Special Tools (Repair Tools) .

Removal Procedure

WARNING: Refer to Diesel/Gasoline Vapors Warning .

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.

Fig. 9: View Of Quick-Connect Fitting Retainer Courtesy of GENERAL MOTORS COMPANY

2. Remove the retainer from the quick-connect fitting.

Fig. 10: Blowing Dirt Out Of Fitting (Metal Collar) Courtesy of GENERAL MOTORS COMPANY

WARNING: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury.

3. Blow dirt out of the fitting using compressed air.

Fig. 11: View Of Quick Connect Locking Tabs (Metal Collar) Courtesy of GENERAL MOTORS COMPANY

4. Depending on the fuel line size and ability to access the fitting, choose the appropriate tool: CH-41769 fuel line disconnect tool set or CH-44581 fuel line disconnect tool. Insert the CH-41769 fuel line disconnect tool set or CH-44581 fuel line disconnect tool into the female connector, then push inward to release the locking tabs.

Fig. 12: View Of Quick Connect Locking Tabs (Metal Collar) Courtesy of GENERAL MOTORS COMPANY

5. Pull the connection apart.

CAUTION: If necessary, remove rust or burrs from the fuel pipes with an emery cloth.

Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required.

6. Using a clean shop towel, wipe off the male pipe end.

7. Inspect both ends of the fitting for dirt and burrs.

8. Clean or replace the components as required.

Installation Procedure

Fig. 13: Oiling Male Pipe Ends (Metal Collar) Courtesy of GENERAL MOTORS COMPANY

WARNING: In 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.

Fig. 14: View Of Connectors (Metal Collar) Courtesy of GENERAL MOTORS COMPANY

2. Push both sides of the quick-connect fitting together to cause the retaining tabs to snap into place.

Fig. 15: Ensuring Connection (Metal Collar) Is Secure Courtesy of GENERAL MOTORS COMPANY

3. Pull on both sides of the quick-connect fitting to make sure the connection is secure.

Fig. 16: View Of Fuel Pipe Retainer

Courtesy of GENERAL MOTORS COMPANY

4. Install the retainer to the quick-connect fitting.

5. Inspect for leaks using the following procedure:

1. Turn the ignition ON, with the engine OFF for 2 seconds.

2. Turn the ignition OFF, for 10 seconds.

3. Turn the ignition ON, with the engine OFF for 2 seconds.

4. Turn the ignition OFF.

5. Inspect for leaks.

PLASTIC COLLAR QUICK CONNECT FITTING SERVICE

Removal Procedure

WARNING: Refer to Diesel/Gasoline Vapors Warning .

NOTE: If servicing a fuel system, insure the fuel pressure has been relieved.

Fig. 17: Plastic Collar Quick Connect Fitting Service Courtesy of GENERAL MOTORS COMPANY

NOTE: There are several types of plastic collar fuel and evaporative emission quick connect fittings used on this vehicle.

Bartholomew (1)

Q Release (2)

Squeeze to Release (3) Sliding Retainer (4)

Global Connect (5)

TI Loc (6)

Safe Lock (7)

Plastic Connector (8)

The following instructions apply to all of these types of plastic collar quick connect fittings except where indicated.

Fig. 18: Blowing Dirt Out Of Fitting (Plastic Collar) Courtesy of GENERAL MOTORS COMPANY

WARNING: Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings. This will ensure proper reconnection and prevent a possible fuel leak. Always replace O-rings.

1. Using compressed air, blow any dirt out of the quick-connect fitting.

Fig. 19: View Of Quick Connect Fitting Release Tabs (Plastic Collar) Courtesy of GENERAL MOTORS COMPANY

2. This step applies to Bartholomew style connectors ONLY. Squeeze the plastic quick-connect fitting release tabs.

Fig. 20: Releasing Q Release Style Connectors (Plastic Collar) Courtesy of GENERAL MOTORS COMPANY

3. This step applies to Q Release style connectors ONLY. Release the fitting by Pushing the tab toward the other side of the slot in the fitting.

Fig. 21: Disengaging Quick Connect Fitting (Plastic Collar) Courtesy of GENERAL MOTORS COMPANY

4. This step applies to Squeeze to Release style connectors ONLY. Squeeze where indicated by arrows on both sides of the plastic ring surrounding the quick-connect fitting.

Fig. 22: Pushing In Male Side Of Connector Courtesy of GENERAL MOTORS COMPANY

5. This step applies to Squeeze to Release style connectors ONLY. Push in the male side slightly in order to slide the retainer away from the retainers, squeeze where indicated by arrows on both sides of the plastic ring surrounding the quick-connect fitting.

Fig. 23: Variants Of Sliding Retainer Style Connectors Courtesy of GENERAL MOTORS COMPANY

NOTE: There are two variants of sliding retainer style connectors shown above, both have the same release and installation procedure.

6. This step applies to Sliding Retainer style connectors ONLY. Release the fitting by pressing on one side of the release tab causing it to push in slightly. If the tab doesn't move try pressing the tab in from the opposite side. The tab will only move in one direction.

Fig. 24: Global Connector Style

Courtesy of GENERAL MOTORS COMPANY

7. This step applies to the Global Connector style only. Push the connector toward the tube in order to release the pressure. Press and hold down the release mechanism, and pull the connector straight out.

Fig. 25: TI Loc style

Courtesy of GENERAL MOTORS COMPANY

8. This step applies to the TI Loc style only. Push the connector toward the tube in order to release the pressure. Release the redundant latch (1) with two fingers or a flat bladed tool. Then press and hold down the bottom release mechanism (2) and pull the connector straight out.

Fig. 26: Safe Lock Style

Courtesy of GENERAL MOTORS COMPANY

WARNING: Refer to Relieving Fuel Pressure Warning .

9. This step applies to the Safe Lock style only. Push the connector toward the tube in order to release the pressure. Release the second latch (1) with two fingers. Then press and hold down the bottom release mechanism (2) and pull the connector straight out.

Fig. 27: Latch And Connector Straight Out Courtesy of GENERAL MOTORS COMPANY

10. This step applies to the Plastic Connector style 8, push the connector toward the tube in order to release the pressure. Press the latch (1) inward in order to release the pipe, while pulling the connector (2) straight out.

11. Using a clean shop towel, wipe off the male pipe end.

12. Inspect both ends of the fitting for dirt and burrs.

13. Clean or replace components as necessary.

Installation Procedure

Fig. 28: Lubricating Male Pipe End

Courtesy of GENERAL MOTORS COMPANY

WARNING: Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings. This will ensure proper reconnection and prevent a possible fuel leak. Always replace O-rings.

1. Apply a few drops of clean engine oil to the male pipe end.

Fig. 29: Connecting Quick-Connect Fittings Courtesy of GENERAL MOTORS COMPANY

2. Push both sides of the quick-connect fitting together in order to cause the retaining feature to snap into place.

Fig. 30: View Of Quick-Connect Fitting Courtesy of GENERAL MOTORS COMPANY

3. Pull on both sides of the quick-connect fitting to make sure the connection is secure.

Fig. 31: TI Loc style

Courtesy of GENERAL MOTORS COMPANY

4. Insert the tube in the connector until the retainer snaps in place.

5. Push down on the redundant latch (1) until it is fully engaged and snapped into position.

Fig. 32: Redundant Latch

Courtesy of GENERAL MOTORS COMPANY

6. Insert the tube in the connector until the retainer snaps in place.

7. Push down on the second latch (1) in order to secure the connection.

Fig. 33: Latch And Connector

Courtesy of GENERAL MOTORS COMPANY

8. For the plastic connector type 8, depress the latch (1) while inserting the connector (3) on to the pipe (2).

9. Move the latch (1) upward in order to secure the connection.

10. Inspect for leaks using the following procedure:

1. Turn the ignition ON, with the engine OFF for 2 seconds.

2. Turn the ignition OFF, for 10 seconds.

3. Turn the ignition ON, with the engine OFF for 2 seconds.

4. Turn the ignition OFF.

5. Inspect for leaks.

EVAPORATIVE EMISSION SYSTEM CLEANING

Special Tools

GE 41413 Evaporative Pressure and Purge Station

For equivalent regional tools, refer to Special Tools (Diagnostic Tools) Special Tools (Repair Tools) .

Inspection Procedure

CAUTION: Use the Evaporative Emission (EVAP) System Tester GE 41413-A in order to provide a clean, dry, low pressure nitrogen gas source. Do not substitute any other pressurized source, gas or otherwise. Damage may result to the EVAP system, test equipment or cause a safety risk.

NOTE: Proceed with the following procedure only if referenced by an evaporative emission diagnostic or repair procedure.

1. Turn OFF the ignition.

2. Remove the evaporative canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement.

3. Lightly tap the evaporative canister purge valve on a hard surface.

4. Inspect for carbon particles exiting either of the vacuum ports.

If no carbon particles were detected, but a blockage was detected during a diagnostic procedure, install the original evaporative canister purge valve. Continue with the cleaning procedure.

If carbon particles are found during the inspection procedure, continue with the cleaning procedure.

If a diagnostic procedure directed you to replace the evaporative canister purge valve and no carbon particles were detected, replace the evaporative canister purge valve. Return to the published service procedure.

Cleaning Procedure

1. Remove the evaporative canister. Refer to Evaporative Emission Canister Replacement.

2. Turn OFF the main valve on the GE 41413 purge station.

3. Disconnect the hose from the diagnostic station pressure regulator.

4. Using a section of vacuum hose, connect one end onto the evaporative pressure/purge diagnostic station pressure regulator.

5. Connect the other end of the vacuum hose to the canister side of the purge pipe.

6. Turn ON the main nitrogen cylinder valve and continue to discharge nitrogen for 15 seconds.

7. If the nitrogen does not clear the blockage, replace the purge pipe.

8. Return the evaporative pressure/purge diagnostic station to the stations original condition.

9. Install a new evaporative canister. Refer to Evaporative Emission Canister Replacement.

10. Install a new evaporative canister purge valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement.

11. Return to the diagnostic table that sent you here.

ENGINE CONTROL MODULE REPLACEMENT

Removal Procedure

CAUTION: Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control

module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage.

Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery.

In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board.

Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module.

The replacement control module must be programmed.

NOTE: It is necessary to record the engine oil life percentage remaining. Use the scan tool to reset the engine oil life remaining back to the original percentage recorded.

1. Prepare the engine control module (ECM) for the replacement. Refer to Control Module References .

2. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining life engine oil life.

3. Disconnect Battery Negative Cable Disconnection and Connection

4. Remove Front Bumper Fascia Removal and Installation

Fig. 34: ECM Electrical Connectors

Courtesy of GENERAL MOTORS COMPANY

CAUTION: In order to prevent any possible electrostatic discharge damage to the ECM, do not touch the connector pins.

5. Disconnect the electrical connectors.(1)

Fig. 35: Engine Control Module And Retaining Tabs Courtesy of GENERAL MOTORS COMPANY

6. Remove Engine Control Module (1) - Unlock the retaining tabs.

Installation Procedure

Fig. 36: Engine Control Module And Retaining Tabs Courtesy of GENERAL MOTORS COMPANY

1. Install Engine Control Module (1)

Fig. 37: ECM Electrical Connectors

Courtesy of GENERAL MOTORS COMPANY

2. Connect the electrical connectors.(1)

3. Install Front Bumper Fascia Removal and Installation

4. Connect Battery Negative Cable Disconnection and Connection

5. Program the ECM. Control Module References

ENGINE CONTROL MODULE BRACKET REPLACEMENT

Removal Procedure

1. Remove Engine Control Module Replacement

Fig. 38: Engine Control Module Bracket, Wiring Harness And Retainers Courtesy of GENERAL MOTORS COMPANY

2. Unclip Wiring Harness(1) @Engine Control Module Bracket (2)

Release Retainer (3)

Fig. 39: Engine Control Module Bracket And Nuts Courtesy of GENERAL MOTORS COMPANY

3. Remove Nut (2)

4. Remove Engine Control Module Bracket (1)

Installation Procedure

Fig. 40: Engine Control Module Bracket And Nuts Courtesy of GENERAL MOTORS COMPANY

1. Install Engine Control Module Bracket (1)

CAUTION: Fastener Caution

2. Install Nut (2) and tighten 9 N.m (80 lb in).

Fig. 41: Engine Control Module Bracket, Wiring Harness And Retainers Courtesy of GENERAL MOTORS COMPANY

3. Install Wiring Harness (1) @Engine Control Module Bracket (2) Tighten Retainer (3)

4. Install Engine Control Module Replacement

CRANKSHAFT POSITION VARIATION LEARN

The Crankshaft Position Variation Learn procedure is required when the following service procedures have been performed, regardless of whether DTC P0315 is set:

An engine replacement.

A engine control module (ECM) replacement. A crankshaft balancer replacement.

A crankshaft replacement.

A crankshaft position sensor replacement.

Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship.

The ECM monitors certain component signals to determine if all the conditions are met to continue with the Crankshaft Position Variation Learn procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool displays the signals of the components listed below:

Crankshaft position sensors activity: If there is a crankshaft position sensor condition, refer to the applicable DTC set.

Camshaft position sensor signal activity: If there is a camshaft position sensor signal condition, refer to the applicable DTC set.

Engine coolant temperature (ECT): If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature.

1. Verify no DTCs are set.

If any DTCs other than P0300 - P0308, or P0315 are set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle .

If DTC P0300 - P0308, P0315, or no DTCs are set

NOTE: The Crankshaft Position Variation Learn may have to be repeated up to 5 times before the procedure is successful.

2. Engine Running at normal operating temperature, perform the scan tool Crankshaft Position Variation Learn procedure and follow the on screen instructions.

3. Verify the scan tool displays Test Passed Successfully when completed.

If Test Passed Successfully is not displayed

Verify that none of the conditions listed below exist:

The ignition switch is in the ON position until there is insufficient system voltage.

An ECM power disconnect with the ignition ON that may have erased the crankshaft position system variation values and set DTC P0315.

Interference in the signal circuit of the crankshaft position sensor.

Debris between the crankshaft position sensor and the reluctor wheel. A damaged or misaligned reluctor wheel.

Worn crankshaft main bearings. Excessive crankshaft runout.

A damaged crankshaft.

If a condition is exists, repair or replace as necessary.

If no conditions exist, replace the K20 Engine Control Module.

If Test Passed Successfully is displayed

4. Clear all DTCs.

5. Engine Running.

6. Verify a DTC is not set.

If a DTC is set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle .

If a DTC is not set

7. All OK.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Control Module References for engine control module replacement, programming, and setup.

ENGINE COOLANT TEMPERATURE SENSOR REPLACEMENT - WATER OUTLET

Removal Procedure

1. Drain the cooling system. Cooling System Draining and Filling

2. Remove Heater Outlet Hose Vapor Vent Hose Replacement

3. Remove Radiator Inlet Hose@Water Outlet Radiator Inlet Hose Replacement

Fig. 42: Heater Outlet Hose Clamp

Courtesy of GENERAL MOTORS COMPANY

4. Loosen Heater Outlet Hose Clamp (2)

5. Disconnect Heater Outlet Hose (1)

Fig. 43: Engine Coolant Temperature Sensor, Electrical Connector, Retainer And Seal Courtesy of GENERAL MOTORS COMPANY

6. Disconnect the engine coolant temperature sensor electrical connector.(3)

7. Remove Engine Coolant Temperature Sensor Retainer (4)

8. Remove the engine coolant temperature sensor.(2)

9. Remove and DISCARD the seal.(1)

Installation Procedure

Fig. 44: Engine Coolant Temperature Sensor, Electrical Connector, Retainer And Seal Courtesy of GENERAL MOTORS COMPANY

1. Install a NEW seal.(1)

2. Install the engine coolant temperature sensor.(2)

3. Install Engine Coolant Temperature Sensor Retainer (4)

4. Connect the engine coolant temperature sensor electrical connector.(3)

Fig. 45: Heater Outlet Hose Clamp

Courtesy of GENERAL MOTORS COMPANY

5. Connect Heater Outlet Hose (1)

6. Tighten Heater Outlet Hose Clamp (2)

7. Install Radiator Inlet Hose@Water Outlet Radiator Inlet Hose Replacement

8. Install Heater Outlet Hose Vapor Vent Hose Replacement

9. Fill the cooling system. Cooling System Draining and Filling

MANIFOLD ABSOLUTE PRESSURE SENSOR REPLACEMENT

Removal Procedure

1. Relieve the fuel system pressure. Fuel Pressure Relief

2. Disconnect Battery Negative Cable Disconnection and Connection

3. Remove Air Inlet Grille Panel Replacement

4. Remove Intake Manifold Cover Replacement

5. Remove Air Cleaner Outlet Duct Replacement

Fig. 46: Air Cleaner Resonator Bracket, Bolt And Wiring Harness Clip Courtesy of GENERAL MOTORS COMPANY

6. Unclip Wiring Harness Clip (3)

7. Remove Air Cleaner Resonator Bracket Bolt (1)

8. Remove Air Cleaner Resonator Bracket (2)

Fig. 47: Fuel Feed Front Pipe And Fuel Injection Pump Courtesy of GENERAL MOTORS COMPANY

9. Disconnect Fuel Feed Front Pipe (2) @Fuel Injection Pump (1)

10. Close all open connections with the EN-6015 plugs.

11. Remove Fuel Feed Front Pipe (2)

Fig. 48: Manifold Absolute Pressure Sensor, Electrical Connector, Bolt And Seal Ring Courtesy of GENERAL MOTORS COMPANY

12. Disconnect the electrical connector.(1)

13. Remove the manifold absolute pressure sensor bolt.(2)

14. Remove the manifold absolute pressure sensor.(3)

15. Remove the seal ring.(4)

Installation Procedure

Fig. 49: Manifold Absolute Pressure Sensor, Electrical Connector, Bolt And Seal Ring Courtesy of GENERAL MOTORS COMPANY

1. Install Seal Ring (4)

2. Install Manifold Absolute Pressure Sensor (3)

CAUTION: Fastener Caution

3. Install Manifold Absolute Pressure Sensor Bolt (2) and tighten 10 N.m (89 lb in)

4. Connect the electrical connector.(1)

Fig. 50: Fuel Feed Front Pipe And Fuel Injection Pump Courtesy of GENERAL MOTORS COMPANY

5. Install Fuel Feed Front Pipe (2)

6. Remove all EN-6015 plugs from the connections.

7. Connect Fuel Feed Front Pipe (2) @Fuel Injection Pump (1)

Fig. 51: Air Cleaner Resonator Bracket, Bolt And Wiring Harness Clip Courtesy of GENERAL MOTORS COMPANY

8. Install Air Cleaner Resonator Bracket (2)

9. Install Air Cleaner Resonator Bracket Bolt (1) and tighten 9 N.m (80 lb in)

10. Install Wiring Harness Clip (3)

11. Install Air Inlet Grille Panel Replacement

12. Install Intake Manifold Cover Replacement

13. Install Air Cleaner Outlet Duct Replacement

14. Connect the negative battery cable. Battery Negative Cable Disconnection and Connection

KNOCK SENSOR REPLACEMENT

Fig. 52: Knock Sensor

Courtesy of GENERAL MOTORS COMPANY

EXHAUST GAS RECIRCULATION VALVE REPLACEMENT

Removal Procedure

1. Remove Exhaust Gas Recirculation Cooler Temperature Sensor Replacement - Position 1

2. Drain the cooling system. Cooling System Draining and Filling

Fig. 53: Engine Wiring Harness Bracket, Bolt, Nut And Electrical Connector Courtesy of GENERAL MOTORS COMPANY

3. Remove Engine Wiring Harness Bracket Bolt (1)

4. Remove Engine Wiring Harness Bracket Nut (3)

5. Position aside Engine Wiring Harness Bracket (4) -

6. Disconnect the electrical connector.(2)

Fig. 54: EGR Valve Bolts, Cooling Return Hose, Clamp And EGR Cooler Bolts Courtesy of GENERAL MOTORS COMPANY

7. Loosen Clamp (6)

8. Disconnect Exhaust Gas Recirculation Valve Cooling Return Hose (5)

9. Remove Exhaust Gas Recirculation Cooler Bolt (4)

10. Exhaust Gas Recirculation Valve Bolt (2, 3)

Fig. 55: Exhaust Gas Recirculation Valve And Gaskets Courtesy of GENERAL MOTORS COMPANY

11. Remove Exhaust Gas Recirculation Valve (1)

12. Remove Gasket (2, 3)

Installation Procedure

Fig. 56: Exhaust Gas Recirculation Valve And Gaskets Courtesy of GENERAL MOTORS COMPANY

1. Install Gasket (2, 3)

2. Install Exhaust Gas Recirculation Valve (1)

Fig. 57: EGR Valve Bolts, Cooling Return Hose, Clamp And EGR Cooler Bolts Courtesy of GENERAL MOTORS COMPANY

3. Install Exhaust Gas Recirculation Valve Bolt (2, 3)

4. Install Exhaust Gas Recirculation Cooler Bolt (4)

CAUTION: Fastener Caution

5. Exhaust Gas Recirculation Valve Bolt (2, 3) - Tighten 10 N.m (89 lb in)

6. Exhaust Gas Recirculation Cooler Bolt (4) - Tighten 10 N.m (89 lb in)

7. Connect Exhaust Gas Recirculation Valve Cooling Return Hose (5)

8. Tighten Clamp (6)

Fig. 58: Engine Wiring Harness Bracket, Bolt, Nut And Electrical Connector Courtesy of GENERAL MOTORS COMPANY

9. Install Engine Wiring Harness Bracket (4)

10. Connect the electrical connector.(2)

11. Install Engine Wiring Harness Bracket Nut (3) and tighten 9 N.m (80 lb in)

12. Install Engine Wiring Harness Bracket Bolt (1) and tighten 9 N.m (80 lb in)

13. Fill the cooling system. Cooling System Draining and Filling

14. Install Exhaust Gas Recirculation Cooler Temperature Sensor Replacement - Position 1

EXHAUST GAS RECIRCULATION COOLER TEMPERATURE SENSOR REPLACEMENT - POSITION 1

Removal Procedure

WARNING: Exhaust Service Warning

1. Disconnect Battery Negative Cable Disconnection and Connection

2. Remove Intake Manifold Cover Replacement

Fig. 59: EGR Cooler Temperature Sensor, Wiring Harness, EGR Cooler, Camshaft Cover Bracket And Electrical Connector

Courtesy of GENERAL MOTORS COMPANY

3. Disconnect the electrical connector.(1)

4. Remove Exhaust Gas Recirculation Cooler Temperature Sensor Wiring Harness@Camshaft Cover Bracket (2)

5. Remove Exhaust Gas Recirculation Cooler Temperature Sensor (4) @Exhaust Gas Recirculation Cooler (3)

Installation Procedure

Fig. 60: EGR Cooler Temperature Sensor, Wiring Harness, EGR Cooler, Camshaft Cover Bracket And Electrical Connector

Courtesy of GENERAL MOTORS COMPANY

CAUTION: Fastener Caution

1. Install Exhaust Gas Recirculation Cooler Temperature Sensor (4) and tighten 42 N.m (31 lb ft)

2. Install Exhaust Gas Recirculation Cooler Temperature Sensor Wiring Harness@Camshaft Cover Bracket (2)

3. Connect the electrical connector.(1)

4. Install Intake Manifold Cover Replacement

5. Connect Battery Negative Cable Disconnection and Connection

EXHAUST GAS RECIRCULATION COOLER TEMPERATURE SENSOR REPLACEMENT - POSITION 2

Removal Procedure

WARNING: Exhaust Service Warning

1. Disconnect Battery Negative Cable Disconnection and Connection

2. Remove Intake Manifold Cover Replacement

3. Remove Three-Way Catalytic Converter Replacement

Fig. 61: EGR Cooler Temperature Sensor, EGR Cooler, Wiring Harness Clip And Electrical Connector

Courtesy of GENERAL MOTORS COMPANY

4. Disconnect the electrical connector.(1)

5. Unclip Exhaust Gas Recirculation Cooler Temperature Sensor (2) @Wiring Harness Clip (4)

6. Remove Exhaust Gas Recirculation Cooler Temperature Sensor (2) @Exhaust Gas Recirculation Cooler (3)

Installation Procedure

Fig. 62: EGR Cooler Temperature Sensor, EGR Cooler, Wiring Harness Clip And Electrical Connector

Courtesy of GENERAL MOTORS COMPANY

CAUTION: Fastener Caution

1. Install Exhaust Gas Recirculation Cooler Temperature Sensor (2) and tighten 42 N.m (31 lb ft)

2. Exhaust Gas Recirculation Cooler Temperature Sensor (2) @Wiring Harness Clip (4)

3. Connect the electrical connector.(1)

4. Install Three-Way Catalytic Converter Replacement

5. Install Intake Manifold Cover Replacement

6. Connect Battery Negative Cable Disconnection and Connection

EXHAUST GAS RECIRCULATION COOLER OUTLET PIPE REPLACEMENT

Removal Procedure

1. Remove Dash Upper Extension Panel Opening Cover Replacement

2. Remove Air Cleaner Outlet Duct Replacement

3. Remove Water Outlet Replacement

4. Remove Three-Way Catalytic Converter Replacement

Fig. 63: EGR Temperature Sensor - Position 2, EGR Cooler And Bolts Courtesy of GENERAL MOTORS COMPANY

5. Remove the exhaust gas recirculation temperature sensor - position 2 (2).

6. Remove Exhaust Gas Recirculation Cooler Bolt (3) @Exhaust Gas Recirculation Cooler (1)

Fig. 64: Exhaust Gas Recirculation Pipe Bolts Courtesy of GENERAL MOTORS COMPANY

7. Remove Exhaust Gas Recirculation Pipe Bolt (1)

Fig. 65: Exhaust Gas Recirculation Cooler Outlet Pipe And Seals Courtesy of GENERAL MOTORS COMPANY

8. Remove Exhaust Gas Recirculation Cooler Outlet Pipe (2)

9. Remove Exhaust Gas Recirculation Cooler Outlet Pipe Seal (1, 3) and DISCARD

Installation Procedure

Fig. 66: Exhaust Gas Recirculation Cooler Outlet Pipe And Seals Courtesy of GENERAL MOTORS COMPANY

1. Install a NEW seal.(1, 3)

2. Install Exhaust Gas Recirculation Cooler Outlet Pipe (3)

Fig. 67: Exhaust Gas Recirculation Pipe Bolts Courtesy of GENERAL MOTORS COMPANY

NOTE: Do NOT tighten.

3. Install Exhaust Gas Recirculation Pipe Bolt (1)

Fig. 68: EGR Temperature Sensor - Position 2, EGR Cooler And Bolts Courtesy of GENERAL MOTORS COMPANY

NOTE: Do NOT tighten.

4. Install Exhaust Gas Recirculation Pipe Bolt (3) @Exhaust Gas Recirculation Cooler (1)

CAUTION: Fastener Caution

5. Exhaust Gas Recirculation Pipe Bolt (3) - Tighten 10 N.m (89 lb in)

Fig. 69: Exhaust Gas Recirculation Pipe Bolts Courtesy of GENERAL MOTORS COMPANY

6. Exhaust Gas Recirculation Cooler Bolt (1) - Tighten 10 N.m (89 lb in)

Fig. 70: EGR Temperature Sensor - Position 2, EGR Cooler And Bolts Courtesy of GENERAL MOTORS COMPANY

7. Install the exhaust gas recirculation temperature sensor - position 2 (2) and tighten to 42 N.m (31 lb ft).

8. Install Three-Way Catalytic Converter Replacement

9. Install Water Outlet Replacement

10. Install Air Cleaner Outlet Duct Replacement

11. Install Dash Upper Extension Panel Opening Cover Replacement

EXHAUST GAS RECIRCULATION VALVE COOLING RETURN HOSE REPLACEMENT

Fig. 71: Exhaust Gas Recirculation Valve Cooling Return Hose Courtesy of GENERAL MOTORS COMPANY

EXHAUST GAS RECIRCULATION COOLER REPLACEMENT

Removal Procedure

1. Drain the cooling system. Cooling System Draining and Filling

2. Remove Three-Way Catalytic Converter Replacement

Fig. 72: EGR Cooler, EGR Cooler Water Bypass Outlet Hose, Heater Inlet Hose And Clamps Courtesy of GENERAL MOTORS COMPANY

3. Loosen Clamp(3)

4. Disconnect Heater Inlet Hose (2)@Exhaust Gas Recirculation Cooler (1)

5. Disconnect Exhaust Gas Recirculation Cooler Water Bypass Outlet Hose (4) @Exhaust Gas Recirculation Cooler (1)

Fig. 73: Thermostat Bypass Hose Clamp Courtesy of GENERAL MOTORS COMPANY

6. Loosen Thermostat Bypass Hose Clamp (1)

7. Disconnect Thermostat Bypass Hose (2)

Fig. 74: EGR Temperature Sensor - Position 1, EGR Cooler And Bolts Courtesy of GENERAL MOTORS COMPANY

8. Remove the exhaust gas recirculation temperature sensor - position 1 (1) from exhaust gas recirculation cooler (3).

9. Remove Exhaust Gas Recirculation Cooler Bolt (2)

Fig. 75: EGR Temperature Sensor - Position 2, EGR Cooler And Bolts Courtesy of GENERAL MOTORS COMPANY

10. Remove the exhaust gas recirculation temperature sensor - position 2 (2).

11. Remove Exhaust Gas Recirculation Cooler Bolt (3) @Exhaust Gas Recirculation Cooler (1)

Fig. 76: EGR Cooler, Bolts And Gaskets Courtesy of GENERAL MOTORS COMPANY

12. Remove Exhaust Gas Recirculation Cooler Bolt (3)

13. Remove Exhaust Gas Recirculation Cooler (4)

14. Remove Gasket (1, 2) and DISCARD

Installation Procedure

Fig. 77: EGR Cooler, Bolts And Gaskets Courtesy of GENERAL MOTORS COMPANY

1. Install a NEW gasket.(1, 2)

2. Install Exhaust Gas Recirculation Cooler (4)

NOTE: Do NOT tighten.

3. Install Exhaust Gas Recirculation Cooler Bolt (3)

Fig. 78: EGR Temperature Sensor - Position 2, EGR Cooler And Bolts Courtesy of GENERAL MOTORS COMPANY

NOTE: Do NOT tighten.

4. Install Exhaust Gas Recirculation Cooler Bolt (3) @Exhaust Gas Recirculation Cooler(1)

CAUTION: Fastener Caution

5. Install the exhaust gas recirculation temperature sensor - position 2 (2) and tighten to 42 N.m (31 lb ft).

Fig. 79: EGR Temperature Sensor - Position 1, EGR Cooler And Bolts Courtesy of GENERAL MOTORS COMPANY

NOTE: Do NOT tighten.

6. Install Exhaust Gas Recirculation Cooler Bolt (2)

7. Install the exhaust gas recirculation temperature sensor - position 1 (1) to the exhaust gas recirculation cooler (3) and tighten to 42 N.m (31 lb ft).

8. Tighten all 6 exhaust gas recirculation cooler bolts to 10 N.m (89 lb in)

Fig. 80: Thermostat Bypass Hose Clamp Courtesy of GENERAL MOTORS COMPANY

9. Connect Thermostat Bypass Hose (2) -

10. Tighten Thermostat Bypass Hose Clamp (1) - Tighten

Fig. 81: EGR Cooler, EGR Cooler Water Bypass Outlet Hose, Heater Inlet Hose And Clamps Courtesy of GENERAL MOTORS COMPANY

11. Connect Heater Inlet Hose (2) @Exhaust Gas Recirculation Cooler (1)

12. Connect Exhaust Gas Recirculation Cooler Water Bypass Outlet Hose (4) @Exhaust Gas Recirculation Cooler (1)

13. Clamp (3) - Tighten

14. Install Three-Way Catalytic Converter Replacement

15. Fill the cooling system. Cooling System Draining and Filling

EXHAUST GAS RECIRCULATION PIPE REPLACEMENT

Fig. 82: Exhaust Gas Recirculation Pipe Courtesy of GENERAL MOTORS COMPANY

THROTTLE BODY ASSEMBLY REPLACEMENT

Removal Procedure

1. Disable the high voltage system. High Voltage Disabling

2. Remove Dash Upper Extension Panel Opening Cover Dash Upper Extension Panel Opening Cover Replacement

3. Remove Air Cleaner Outlet Duct Air Cleaner Outlet Duct Replacement

Fig. 83: Throttle Body, Electrical Connector And Bolts Courtesy of GENERAL MOTORS COMPANY

4. Disconnect Electrical Connector (2)

5. Remove Throttle Body Bolt (1)

6. Remove Throttle Body (3)

Fig. 84: Gasket And Intake Manifold

Courtesy of GENERAL MOTORS COMPANY

7. Remove Throttle Body Gasket (1)and DISCARD

Installation Procedure

Fig. 85: Gasket And Intake Manifold

Courtesy of GENERAL MOTORS COMPANY

1. Clean the intake manifold mating surfaces.(2)

2. Install NEW Throttle Body Gasket (1)

Fig. 86: Throttle Body, Electrical Connector And Bolts Courtesy of GENERAL MOTORS COMPANY

3. Install Throttle Body (3)

CAUTION: Refer to Fastener Caution .

4. Install Throttle Body Bolt (1) and tighten 10 N.m (89 lb in)

5. Connect Electrical Connector (2)

6. Install Air Cleaner Outlet Duct Air Cleaner Outlet Duct Replacement

7. Install Dash Upper Extension Panel Opening Cover Dash Upper Extension Panel Opening Cover Replacement

8. Enable the high voltage system. High Voltage Disabling

9. Perform the throttle or idle learn. Throttle or Idle Learn

THROTTLE BODY INSPECTION AND CLEANING

1. Remove Throttle Body Assembly Replacement

WARNING: Turn OFF the ignition before inserting fingers into the throttle bore.

Unexpected movement of the throttle blade could cause personal injury.

CAUTION: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate.

NOTE: Open the throttle valve in order to inspect all surfaces.

2. Inspect the throttle body bore and the throttle valve plate for deposits.

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

3. Clean the throttle body bore and the throttle valve plate using a clean shop towel with an appropriate cleaner.

4. Install Throttle Body Assembly Replacement.

5. Throttle or Idle Learn

FUEL PRESSURE RELIEF

WARNING: Fuel that flows out at high pressure can cause serious injury to the skin and eyes. ALWAYS depressurize the fuel system before removing components that are under high fuel pressure.

WARNING: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out.

Place the towel in an approved container when the disconnection is complete.

Scan Tool Method - Preferred

1. Install a scan tool and turn the ignition ON.

2. Using the scan tool, command the fuel pump OFF allowing the low pressure fuel pump to shut off.

3. Start the vehicle and allow the engine to idle until the engine stops. The engine will stop in approximately 5-20 seconds.

4. Repeat step 3. Using the scan tool, verify pressure has dropped to a minimal level.

5. Turn the ignition OFF.

Alternate Method - If a scan tool is not available

1. Disable the fuel pump by removing the B+ fuel pump control module fuse. Refer to Electrical Center Identification Views .

2. Start the vehicle and allow the engine to idle until the engine stops. The engine will stop in approximately 5-20 seconds.

3. Attempt to restart the vehicle to ensure pressure has dropped to a minimal level.

4. Turn the ignition OFF.

FUEL TANK DRAINING

Special Tool

CH 45004 Fuel Tank Drain Hose

WARNING: Never drain or store fuel in an open container. Always use an approved fuel storage container in order to reduce the chance of fire or explosion.

WARNING: Place a dry chemical (Class B) fire extinguisher nearby before performing any

on-vehicle service procedures. Failure to follow these precautions may result in personal injury.

1. Remove the fuel fill cap.

Fig. 87: Draining Fuel Tank

Courtesy of GENERAL MOTORS COMPANY

NOTE: Lubricate the fuel drain hose with Transjel Lubricant or equivalent to aid in hose insertion.

2. Insert the CH 45004 hose into the fuel tank until the bottom is reached.

3. Use a hand or air operated pump device in order to drain as much fuel through the fuel fill pipe as possible.

FUEL TANK FILLER PIPE REPLACEMENT

Special Tools

EN-6015 Closure Plugs

Equivalent regional tools:Special Tools (Diagnostic Tools) Special Tools (Repair Tools)

Removal Procedure

WARNING: Diesel/Gasoline Vapors Warning WARNING: Safety Goggles and Fuel Warning

1. Disconnect Battery Negative Cable Disconnection and Connection

2. Drain the fuel tank. Fuel Tank Draining

3. Remove Fuel Tank Filler Pipe Housing Replacement

Fig. 88: Fuel Tank Filler Pipe Bolt

Courtesy of GENERAL MOTORS COMPANY

4. Remove Fuel Tank Filler Pipe Bolt (1)

5. Raise and support the vehicle. Lifting and Jacking the Vehicle

6. Remove Rear Wheelhouse Liner Replacement - Right Side

Fig. 89: Fuel Tank Filler Pipe Ground Bolt And Wiring Harness Clip Courtesy of GENERAL MOTORS COMPANY

7. Remove Fuel Tank Filler Pipe Ground Bolt (1)

8. Remove Wiring Harness Clip (2)

Fig. 90: Evaporative Emission System Vacuum Leak Pump Filter Pipe, Fuel Tank Filler Hose, Vent Pipe, Clamp And Retainer

Courtesy of GENERAL MOTORS COMPANY

9. Disconnect the evaporative emission system vacuum leak pump filter pipe (6). Refer to Plastic Collar Quick Connect Fitting Service.

10. Close all open connections with the EN-6015 plugs.

11. Disconnect the fuel tank vent pipe (3). Refer to Plastic Collar Quick Connect Fitting Service.

12. Close all open connections with the EN-6015 plugs.

13. Loosen the clamp.(4)

14. Remove Retainer (1)

Fig. 91: Fuel Tank Filler Pipe

Courtesy of GENERAL MOTORS COMPANY

15. Fuel Tank Filler Pipe (1)

Installation Procedure

Fig. 92: Fuel Tank Filler Pipe

Courtesy of GENERAL MOTORS COMPANY

1. Install Fuel Tank Filler Pipe (1)

Fig. 93: Evaporative Emission System Vacuum Leak Pump Filter Pipe, Fuel Tank Filler Hose, Vent Pipe, Clamp And Retainer

Courtesy of GENERAL MOTORS COMPANY

2. Install the fuel tank filler hose (5) onto the fuel tank.

Fig. 94: Ensure Filler Hose Is Fully Seated And Installed Correctly Courtesy of GENERAL MOTORS COMPANY

3. Make sure that the hose is fully seated on the fuel tank. Filler hose is correctly installed when the end of the hose is even with where the fill spud on the tank increases in diameter. The gap (1) between the tank and the end of hose will be (a) 6 mm (1/4 in) when hose is correctly installed.

Fig. 95: Evaporative Emission System Vacuum Leak Pump Filter Pipe, Fuel Tank Filler Hose, Vent Pipe, Clamp And Retainer

Courtesy of GENERAL MOTORS COMPANY

CAUTION: Fastener Caution

4. Tighten the clamp.(4) 3.5 N.m (31 lb in)

5. Remove all EN-6015 plugs from the connections.

6. Connect the fuel tank vent pipe (3). Refer to Plastic Collar Quick Connect Fitting Service.

7. Remove all EN-6015 plugs from the connections.

8. Connect the evaporative emission system vacuum leak pump filter pipe (6). Refer to Plastic Collar Quick Connect Fitting Service.

9. Install Retainer (1)

Fig. 96: Fuel Tank Filler Pipe Ground Bolt And Wiring Harness Clip Courtesy of GENERAL MOTORS COMPANY

10. Install Fuel Tank Filler Pipe Ground Bolt (1) and tighten 9 N.m (80 lb in)

11. Install Wiring Harness Clip (2)

12. Install Rear Wheelhouse Liner Replacement - Right Side

13. Lower the vehicle.

Fig. 97: Fuel Tank Filler Pipe Bolt

Courtesy of GENERAL MOTORS COMPANY

14. Install Fuel Tank Filler Pipe Bolt (1) and tighten 9 N.m (80 lb in)

15. Connect Fuel Tank Filler Pipe Housing Replacement

16. Refill the fuel tank.

17. Connect Battery Negative Cable Disconnection and Connection

FUEL FEED PIPE REPLACEMENT

Special Tools

EN-6015 Closure Plugs

Equivalent regional tools:Special Tools (Diagnostic Tools) Special Tools (Repair Tools)

Removal Procedure

WARNING: Diesel/Gasoline Vapors Warning WARNING: Safety Goggles and Fuel Warning

1. Relieve the fuel system pressure. Fuel Pressure Relief

2. Disconnect Battery Negative Cable Disconnection and Connection

Fig. 98: Fuel Feed Front Pipe, Fuel Feed Pipe And Retainer Courtesy of GENERAL MOTORS COMPANY

3. Disconnect Fuel Feed Front Pipe (3) @Fuel Feed Pipe (2) -Metal Collar Quick Connect Fitting Service

4. Close all open connections with the EN-6015 plugs.

5. Open the retainer (1).

6. Remove Fuel Feed Pipe (2) @Retainer (1)

7. Raise and support the vehicle. Lifting and Jacking the Vehicle

8. Remove Underbody Rear Air Deflector Replacement

9. Remove Underbody Front Air Deflector Replacement - Left Side

10. Remove Drivetrain and Front Suspension Cradle Replacement

Fig. 99: Fuel Feed Pipe And Retainers Courtesy of GENERAL MOTORS COMPANY

11. Open the 2 retainers (1).

12. Remove Fuel Feed Pipe (2) @Retainer (1)

Fig. 100: Fuel Feed Pipe, Retainer And Electrical Connector Courtesy of GENERAL MOTORS COMPANY

13. Open the retainer (1).

14. Fuel Feed Pipe (3) @Retainer (1)

15. Disconnect the electrical connector.(2)

Fig. 101: Fuel Feed Pipe, Fuel Pump Fuel Feed Hose And Retainer Courtesy of GENERAL MOTORS COMPANY

16. Open the retainer (2).

17. Disconnect Fuel Feed Pipe (1) @Fuel Pump Fuel Feed Hose (3) Plastic Collar Quick Connect Fitting Service

18. Close all open connections with the EN-6015 plugs.

19. Remove Fuel Feed Pipe (1) @Retainer (2)

Fig. 102: Fuel Feed Pipe And Retainers Courtesy of GENERAL MOTORS COMPANY

20. Open the 3 retainers (1).

21. Remove Fuel Feed Pipe (2) @Retainer (1)

22. Remove the fuel feed pipe (2) from the vehicle.

Installation Procedure

Fig. 103: Fuel Feed Pipe And Retainers Courtesy of GENERAL MOTORS COMPANY

1. Install the fuel feed pipe (2) to the vehicle.

2. Install Fuel Feed Pipe (2) @Retainer(1)

3. Close the 3 retainers (1).

Fig. 104: Fuel Feed Pipe, Fuel Pump Fuel Feed Hose And Retainer Courtesy of GENERAL MOTORS COMPANY

4. Install Fuel Feed Pipe(1)@Retainer(2)

5. Remove all EN-6015 plugs from the connections.

6. Connect Fuel Feed Pipe(1)@Fuel Pump Fuel Feed Hose(3)Plastic Collar Quick Connect Fitting Service

7. Close the retainer (2).

Fig. 105: Fuel Feed Pipe, Retainer And Electrical Connector Courtesy of GENERAL MOTORS COMPANY

8. Connect the electrical connector.(2)

9. Install Fuel Feed Pipe(3)@Retainer(1)

10. Close the retainer (1).

Fig. 106: Fuel Feed Pipe And Retainers Courtesy of GENERAL MOTORS COMPANY

11. Install Fuel Feed Pipe(2)@Retainer(1)

12. Close the 2 retainers (1).

13. Install Drivetrain and Front Suspension Cradle Replacement

14. Install Underbody Front Air Deflector Replacement - Left Side

15. Install Underbody Rear Air Deflector Replacement

16. Lower the vehicle.

Fig. 107: Fuel Feed Front Pipe, Fuel Feed Pipe And Retainer Courtesy of GENERAL MOTORS COMPANY

17. Install Fuel Feed Pipe (2) @Retainer (1)

18. Close the retainer (1).

19. Remove all EN-6015 plugs from the connections.

20. Connect Fuel Feed Front Pipe (3) @Fuel Feed Pipe (2)Metal Collar Quick Connect Fitting Service

21. Connect Battery Negative Cable Disconnection and Connection

22. Cycle the ignition to run the fuel pump and check for fuel leaks.

FUEL TANK FUEL PUMP MODULE REPLACEMENT

Special Tools

CH-45722 Fuel Sender Lock Ring Wrench

Equivalent regional tools:Special Tools (Diagnostic Tools) Special Tools (Repair Tools)

Removal Procedure

WARNING: Safety Goggles and Fuel Warning WARNING: Diesel/Gasoline Vapors Warning

WARNING: Fuel Vapors in Evaporative Emission Components Warning

1. Remove Fuel Tank Replacement

Fig. 108: Fuel Pump Feed Hose, Evaporative Emission Canister Hose, Evaporative Emission Rear Hose, Electrical Connector, Fuel Pump Module Wiring Harness And Retainers

Courtesy of GENERAL MOTORS COMPANY

2. Remove Retainer (2, 5, 7)

3. Remove Fuel Pump Fuel Feed Hose (8) Plastic Collar Quick Connect Fitting Service

4. Remove the evaporative emission canister hose (1). Refer to Plastic Collar Quick Connect Fitting Service.

5. Remove Evaporative Emission Rear Hose (3) Plastic Collar Quick Connect Fitting Service

6. Disconnect the electrical connector (6) and remove the fuel tank fuel pump module wiring harness (4).

Fig. 109: Fuel Pump Module Lock Ring And Wrench Courtesy of GENERAL MOTORS COMPANY

7. Install the CH-45722 wrench (1) to the fuel pump module lock ring (2).

NOTE: DO NOT use impact tools. Significant force will be required to release the

lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.

8. Using the CH-45722 wrench (1) and a long breaker-bar, rotate the lock ring in a counterclockwise direction in order to unlock the lock ring.

9. Remove the CH-45722 wrench (1).

10. Remove the fuel pump module lock ring (2).

Fig. 110: Fuel Pump Module And Vent Valve Connector Courtesy of GENERAL MOTORS COMPANY

11. Partially raise the fuel pump module (1) and disconnect the vent valve connector (2). Refer to Plastic Collar Quick Connect Fitting Service.

Fig. 111: Fuel Tank Fuel Pump Module And Seal Courtesy of GENERAL MOTORS COMPANY

NOTE: Lift the fuel tank fuel pump module up slightly. Pay attention to the fuel

level sensor.

12. Remove Fuel Tank Fuel Pump Module (1)

13. Remove and DISCARD the fuel pump module seal (2).

Installation Procedure

Fig. 112: Fuel Tank Fuel Pump Module And Seal Courtesy of GENERAL MOTORS COMPANY

1. Install a NEW fuel pump module seal (2).

NOTE: Pay attention to the fuel level sensor.

2. Install Fuel Tank Fuel Pump Module (1)

Fig. 113: Fuel Pump Module And Vent Valve Connector Courtesy of GENERAL MOTORS COMPANY

3. Connect the vent valve connector (2). Refer to Plastic Collar Quick Connect Fitting Service.

Fig. 114: Fuel Pump Module Lock Ring And Wrench Courtesy of GENERAL MOTORS COMPANY

4. Install the fuel pump module lock ring (2).

5. Install the CH-45722 wrench (1) to the fuel pump module lock ring (2).

NOTE: DO NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended.

Secure the fuel tank in order to prevent fuel tank rotation.

6. Using the CH-45722 wrench (1) and a long breaker bar, rotate the lock ring in a clockwise direction in order to lock the lock ring.

7. Remove the CH-45722 wrench (1).

Fig. 115: Fuel Pump Feed Hose, Evaporative Emission Canister Hose, Evaporative Emission Rear Hose, Electrical Connector, Fuel Pump Module Wiring Harness And Retainers

Courtesy of GENERAL MOTORS COMPANY

8. Connect the electrical connector (6).

9. Install Evaporative Emission Rear Hose (3) -Plastic Collar Quick Connect Fitting Service

10. Install the evaporative emission canister hose (1). Refer to Plastic Collar Quick Connect Fitting Service.

11. Install Fuel Pump Fuel Feed Hose (8) - Plastic Collar Quick Connect Fitting Service

12. Install Retainer(2, 5, 7)

13. Install Fuel Tank Replacement

FUEL TANK REPLACEMENT

Special Tools

EN-6015 Closure Plugs

Equivalent regional tools:Special Tools (Diagnostic Tools) Special Tools (Repair Tools)

Removal Procedure

WARNING: Ensure all High Voltage safety procedures are followed. Failure to follow the procedure exactly as written may result in serious injury or death.

WARNING: Fuel Vapors in Evaporative Emission Components Warning WARNING: Diesel/Gasoline Vapors Warning

WARNING: Safety Goggles and Fuel Warning

1. Relieve the fuel pressure:Fuel Pressure Relief

2. Disconnect Battery Negative Cable Disconnection and Connection

3. Fuel Tank Draining

4. Raise and support the vehicle. Lifting and Jacking the Vehicle

5. Remove Underbody Rear Air Deflector Replacement

6. Remove Underbody Front Air Deflector Replacement - Left Side

Fig. 116: Evaporative Emission Rear Hose, Fuel Tank Filler Hose, Vent Pipe, Electrical Connector, Retainer And Clamp

Courtesy of GENERAL MOTORS COMPANY

7. Disconnect Evaporative Emission Rear Hose (1) - Plastic Collar Quick Connect Fitting Service

8. Close all open connections with the EN-6015 plugs.

9. Disconnect the fuel tank fuel pump module wiring harness electrical connector (2).

10. Open the retainer (6).

11. Disconnect Fuel Tank Filler Vent Pipe (3) - Plastic Collar Quick Connect Fitting Service

12. Close all open connections with the EN-6015 plugs.

13. Loosen Clamp (5)

Fig. 117: Fuel Tank Filler Pipe Ground Bolt And Wiring Harness Clip Courtesy of GENERAL MOTORS COMPANY

14. Remove Fuel Tank Filler Pipe Ground Bolt (1)

Fig. 118: Evaporative Emission Rear Hose, Fuel Tank Filler Hose, Vent Pipe, Electrical Connector, Retainer And Clamp

Courtesy of GENERAL MOTORS COMPANY

15. Remove Fuel Tank Filler Hose (4)

Fig. 119: Fuel Feed Pipe

Courtesy of GENERAL MOTORS COMPANY

16. Disconnect Fuel Feed Pipe (1) -Plastic Collar Quick Connect Fitting Service

17. Close all open connections with the EN-6015 plugs.

18. Remove rear coil springs. Refer to Rear Coil Spring Replacement

Fig. 120: Shock And Lower Shock Fasteners Courtesy of GENERAL MOTORS COMPANY

19. Reinstall the lower shock fasteners (2) to the shock (1) without the coil springs.

20. Support the rear axle with a suitable jack stand.

Fig. 121: Right Side Axle Bracket Bolts Courtesy of GENERAL MOTORS COMPANY

21. Remove and DISCARD the 3 right side axle bracket bolts (1).

Fig. 122: Left Side Rear Axle Bracket Bolts Courtesy of GENERAL MOTORS COMPANY

22. Loosen the 3 left side axle bracket bolts (1). Do not remove the bolts at this time.

Fig. 123: Front Of Axle

Courtesy of GENERAL MOTORS COMPANY

23. Lower the front (1) of the axle and position rearward enough to allow the fuel tank to be removed.

Fig. 124: Fuel Tank Straps

Courtesy of GENERAL MOTORS COMPANY

24. Support the fuel tank with a suitable jack.(3)

25. Remove the 4 fuel tank strap bolts (2, 4).

26. Remove Fuel Tank Strap (1)

Fig. 125: Fuel Tank And Suitable Jack Courtesy of GENERAL MOTORS COMPANY

NOTE: A second technician is required.

27. Move the fuel tank (1) rearwards until there is enough space between the fuel tank (1) and the fuel tank strap bracket (2).

28. Lower the fuel tank (1) slowly using the suitable adjustable jack (3).

Disassemble Procedure

Fig. 126: Fuel Pump Feed Hose, Evaporative Emission Canister Hose, Evaporative Emission Rear Hose, Electrical Connector, Fuel Pump Module Wiring Harness And Retainers

Courtesy of GENERAL MOTORS COMPANY

1. Remove Retainer (2, 5, 7)

2. Remove Fuel Pump Fuel Feed Hose (8) -Plastic Collar Quick Connect Fitting Service

3. Remove the evaporative emission canister hose (1). Refer to Plastic Collar Quick Connect Fitting Service.

4. Remove Evaporative Emission Rear Hose (3) Plastic Collar Quick Connect Fitting Service

5. Disconnect the electrical connector (6) and remove the fuel tank fuel pump module wiring harness (4).

6. Remove Fuel Tank Fuel Pump Module Replacement

Fig. 127: Fuel Tank Heat Shield

Courtesy of GENERAL MOTORS COMPANY

7. Remove Fuel Tank Heat Shield (1)

Assemble Procedure

Fig. 128: Fuel Tank Heat Shield

Courtesy of GENERAL MOTORS COMPANY

1. Install Fuel Tank Heat Shield (1)

2. Install Fuel Tank Fuel Pump Module Replacement

Fig. 129: Fuel Pump Feed Hose, Evaporative Emission Canister Hose, Evaporative Emission Rear Hose, Electrical Connector, Fuel Pump Module Wiring Harness And Retainers

Courtesy of GENERAL MOTORS COMPANY

3. Connect the electrical connector (6).

4. Install Evaporative Emission Rear Hose (3) Plastic Collar Quick Connect Fitting Service

5. Install the evaporative emission canister hose (1). Refer to Plastic Collar Quick Connect Fitting Service.

6. Install Fuel Pump Fuel Feed Hose (8) Plastic Collar Quick Connect Fitting Service

7. Install Retainer (2, 5, 7)

Installation Procedure

Fig. 130: Fuel Tank And Suitable Jack Courtesy of GENERAL MOTORS COMPANY

NOTE: A second technician is required.

1. Raise the fuel tank (1) slowly using the suitable adjustable jack (3).

2. Move the fuel tank (1) forwards.

Fig. 131: Fuel Tank Straps

Courtesy of GENERAL MOTORS COMPANY

3. Install Fuel Tank Strap (1)

CAUTION: Fastener Caution

4. Install the 4 fuel tank strap bolts (2, 4) and tighten to 22 N.m (16 lb ft).

5. Remove the suitable jack (3) from the fuel tank.

6. Return the rear axle to its original position.

7. Support the rear axle with a suitable jack stand.

Fig. 132: Right Side Axle Bracket Bolts Courtesy of GENERAL MOTORS COMPANY

WARNING: Refer to Torque-to-Yield Fastener Warning . CAUTION: Fastener Caution

8. Install 3 NEW right side axle bracket bolts (1). Rear Axle Bracket Replacement

Fig. 133: Left Side Axle Bracket Bolts

Courtesy of GENERAL MOTORS COMPANY

9. Remove and DISCARD the left side axle bracket bolts. Install 3 NEW left side axle bracket bolts (1).

Rear Axle Bracket Replacement

Fig. 134: Shock And Lower Shock Fasteners Courtesy of GENERAL MOTORS COMPANY

10. Support the rear axle and remove the lower shock bolt (2).

11. Install the rear coil springs. Refer to Rear Coil Spring Replacement .

Fig. 135: Fuel Feed Pipe

Courtesy of GENERAL MOTORS COMPANY

12. Remove the EN-6015 plugs.

13. Connect Fuel Feed Pipe (1) Plastic Collar Quick Connect Fitting Service

Fig. 136: Evaporative Emission Rear Hose, Fuel Tank Filler Hose, Vent Pipe, Electrical Connector, Retainer And Clamp

Courtesy of GENERAL MOTORS COMPANY

14. Install Fuel Tank Filler Hose (4)

Fig. 137: Ensure Filler Hose Is Fully Seated And Installed Correctly Courtesy of GENERAL MOTORS COMPANY

15. Make sure that the hose is fully seated on the fuel tank. Filler hose is correctly installed when the end of the hose is even with where the fill spud on the tank increases in diameter. The gap (1) between the tank and the end of hose will be (a) 6 mm (1/4 in) when hose is correctly installed.

Fig. 138: Evaporative Emission Rear Hose, Fuel Tank Filler Hose, Vent Pipe, Electrical Connector, Retainer And Clamp

Courtesy of GENERAL MOTORS COMPANY

16. Clamp (5) - Tighten 3.5 N.m (31 lb in)

Fig. 139: Fuel Tank Filler Pipe Ground Bolt And Wiring Harness Clip Courtesy of GENERAL MOTORS COMPANY

17. Install Fuel Tank Filler Pipe Ground Bolt (1) and tighten 9 N.m (80 lb in)

Fig. 140: Evaporative Emission Rear Hose, Fuel Tank Filler Hose, Vent Pipe, Electrical Connector, Retainer And Clamp

Courtesy of GENERAL MOTORS COMPANY

18. Remove the EN-6015 plugs.

19. Connect Fuel Tank Filler Vent Pipe (3)Plastic Collar Quick Connect Fitting Service

20. Close the retainer (6).

21. Connect the fuel tank fuel pump module wiring harness electrical connector (2).

22. Remove the EN-6015 plugs.

23. Connect Evaporative Emission Rear Hose (1)Plastic Collar Quick Connect Fitting Service

24. Install Underbody Front Air Deflector Replacement - Left Side

25. Install Underbody Rear Air Deflector Replacement

26. Lower the vehicle.

27. Refill the fuel tank.

28. Connect Battery Negative Cable Disconnection and Connection

29. Cycle the ignition to run the fuel pump and check for fuel leaks.

FUEL TANK PRESSURE SENSOR REPLACEMENT

Fig. 141: Fuel Tank Pressure Sensor

Courtesy of GENERAL MOTORS COMPANY

FUEL PUMP FUEL FEED HOSE REPLACEMENT

Special Tools

EN-6015 Closure Plugs

Equivalent regional tools:Special Tools (Diagnostic Tools) Special Tools (Repair Tools)

Removal Procedure

WARNING: Diesel/Gasoline Vapors Warning WARNING: Safety Goggles and Fuel Warning

1. Relieve the fuel system pressure. Fuel Pressure Relief

2. Battery Negative Cable Disconnection and Connection - Disconnect

3. Lower the fuel tank, to get enough space to remove the fuel pipe. Refer to Fuel Tank Replacement.

Fig. 142: Fuel Tank Fuel Pump Module, Fuel Pump Fuel Feed Hose And Retainer Courtesy of GENERAL MOTORS COMPANY

4. Disconnect Fuel Pump Fuel Feed Hose (2) @Fuel Tank Fuel Pump Module (1) -Plastic Collar Quick Connect Fitting Service

5. Close all open connections with the EN-6015 plugs.

6. Unclip Fuel Pump Fuel Feed Hose (2) @Retainer (3)

Installation Procedure

Fig. 143: Fuel Tank Fuel Pump Module, Fuel Pump Fuel Feed Hose And Retainer Courtesy of GENERAL MOTORS COMPANY

1. Install Fuel Pump Fuel Feed Hose (2) @Retainer (3)

2. Remove the EN-6015 plugs from all connections.

3. Connect Fuel Pump Fuel Feed Hose (2) @Fuel Tank Fuel Pump Module (1) -Plastic Collar Quick Connect Fitting Service

4. Install Fuel Tank Replacement

5. Connect Battery Negative Cable Disconnection and Connection

6. Cycle the ignition to run the fuel pump and check for fuel leaks.

FUEL INJECTION FUEL RAIL ASSEMBLY REPLACEMENT

Special Tools

EN-51146 Fuel Injector Removal / Installation Kit

Equivalent regional tools: Special Tools (Diagnostic Tools) Special Tools (Repair Tools) .

Removal Procedure

WARNING: Diesel/Gasoline Vapors Warning WARNING: Safety Goggles and Fuel Warning

CAUTION: When working on the fuel rail and fuel injectors, always maintain a clean work surface. Failure to maintain a clean work surface can result in contaminant on the injector seals and cause leaks.

1. Remove Fuel Injection Fuel Rail Assembly Removal and Installation

Fig. 144: Plate, Bolts And Supports

Courtesy of GENERAL MOTORS COMPANY

NOTE: The EN-51146 - 2 - 5 calibrations tools must be installed.

2. Remove the 8 plate bolts (1) and remove the EN-51146-1-2 plate (2), counterhold with a wrench (4) at the EN-51146-1-1 supports (3).

3. Remove the 8 EN-51146-1-1 supports (3).

Fig. 145: Fuel Injection Fuel Rail, Fuel Injector And Wiring Harness Courtesy of GENERAL MOTORS COMPANY

4. Disconnect Fuel Injector Wiring Harness (2)

5. Remove Fuel Injector (3) @Fuel Injection Fuel Rail (1)

Fig. 146: Fuel Injector And O-Ring

Courtesy of GENERAL MOTORS COMPANY

6. Remove O-Ring (1) @Fuel Injector (2) and DISCARD

Cleaning Procedure

Clean the fuel injector bores. If the fuel injectors will be reused, clean the fuel injectors. Fuel Injection Fuel Rail Assembly Removal and Installation.

Installation Procedure

Fig. 147: Fuel Injector And O-Ring

Courtesy of GENERAL MOTORS COMPANY

1. Coat the fuel injector seals with engine oil.(1)

NOTE: The EN-51146 - 2 - 5 calibrations tools must be installed.

2. Install O-Ring (1) @Fuel Injector (2)

Fig. 148: Fuel Injection Fuel Rail, Fuel Injector Wiring Harness Connectors, Fuel Injectors And Bolts

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do NOT reuse the old bolt.

3. Install Fuel Injector (3) @Fuel Injection Fuel Rail (1)

4. Apply thread locking adhesive to the NEW fuel injector bolts.(4)Adhesives, Fluids, Lubricants, and Sealers

CAUTION: Fastener Caution NOTE: Install NEW bolts.

5. Install Fuel Injector Bolt (4) @Fuel Injector(3) and tighten 5 N.m (44 lb in)

6. Connect Fuel Injector Wiring Harness (2)

7. Install Fuel Injection Fuel Rail Assembly Removal and Installation

FUEL INJECTOR REPLACEMENT

Special Tools

EN-51146 Fuel Injector Removal / Installation Kit

Equivalent regional tools:Special Tools (Diagnostic Tools) Special Tools (Repair Tools) .

Removal Procedure

WARNING: Diesel/Gasoline Vapors Warning WARNING: Safety Goggles and Fuel Warning

CAUTION: When working on the fuel rail and fuel injectors, always maintain a clean work surface. Failure to maintain a clean work surface can result in contaminant on the injector seals and cause leaks.

1. Remove Fuel Injection Fuel Rail Assembly Removal and Installation

Fig. 149: Plate, Bolts And Supports

Courtesy of GENERAL MOTORS COMPANY

NOTE: The EN-51146 - 2 - 5 calibrations tools must be installed.

2. Remove the 8 plate bolts (1) and remove the EN-51146-1-2 plate (2), counterhold with a wrench (4) at the EN-51146-1-1 supports (3).

3. Remove the 8 EN-51146-1-1 supports (3).

Fig. 150: Fuel Injection Fuel Rail, Fuel Injector And Wiring Harness Courtesy of GENERAL MOTORS COMPANY

4. Disconnect Fuel Injector Wiring Harness (2)

5. Remove Fuel Injector(3)@Fuel Injection Fuel Rail(1)

Fig. 151: Fuel Injector And O-Ring

Courtesy of GENERAL MOTORS COMPANY

6. Remove O-Ring (1) @Fuel Injector (2) and DISCARD

Cleaning Procedure

1. Clean the fuel injector bores. If the fuel injectors will be reused, clean the fuel injectors. Fuel Injection Fuel Rail Assembly Removal and Installation.

2. Inspect the NEW fuel injector. Fuel Injection Fuel Rail Assembly Removal and Installation.

Installation Procedure

Fig. 152: Fuel Injector And O-Ring

Courtesy of GENERAL MOTORS COMPANY

1. Coat the fuel injector seals with engine oil.(1)

NOTE: The EN-51146 - 2 - 5 calibrations tools must be installed.

2. Install O-Ring (1) @ Fuel Injector (2)

Fig. 153: Fuel Injection Fuel Rail, Fuel Injector Wiring Harness Connectors, Fuel Injectors And Bolts

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do NOT reuse the old bolt.

3. Install Fuel Injector(3) @Fuel Injection Fuel Rail (1)

4. Apply thread locking adhesive to the NEW fuel injector bolts.(4)Adhesives, Fluids, Lubricants, and Sealers

CAUTION: Fastener Caution NOTE: Install NEW bolts.

5. Install Fuel Injector Bolt (4) @Fuel Injector (3) and tighten 5 N.m (44 lb in)

6. Connect Fuel Injector Wiring Harness(2)

7. Install Fuel Injection Fuel Rail Assembly Removal and Installation

FUEL INJECTOR WIRING HARNESS REPLACEMENT

Removal Procedure

1. Remove Fuel Injection Fuel Rail Assembly Replacement

Fig. 154: Fuel Injector Wiring Harness Components Courtesy of GENERAL MOTORS COMPANY

2. Cut the cable tie (3).

3. Disconnect the fuel injection fuel rail fuel pressure sensor wiring harness electrical connector (2) from the fuel rail fuel pressure sensor (4).

4. Remove and DISCARD the 4 insulating tape stripes (1, 5).

5. Disconnect the 4 fuel injector wiring harness electrical connectors (9, 11) from the fuel injectors (10).

6. Clip out the fuel injector wiring harness (6) from the fuel rail (7).

7. Cut the 4 cable ties (8, 12).

Installation Procedure

Fig. 155: Fuel Injector Wiring Harness Components Courtesy of GENERAL MOTORS COMPANY

1. Connect the 4 fuel injector wiring harness electrical connectors (9, 11) to the 4 fuel injectors (10).

2. Clip in the fuel injector wiring harness (6) to the fuel rail (7).

3. Install NEW 4 cable ties (8, 12) to the position where they have been removed.

4. Connect the fuel injection fuel rail fuel pressure sensor wiring harness plug (2) to the fuel rail fuel pressure sensor (4).

5. Install a NEW cable tie (3) to the position where it have been removed.

6. Install 4 NEW insulating tape stripes (1, 5) to the position where it have been removed.

7. Install Fuel Injection Fuel Rail Assembly Replacement

FUEL INJECTION FUEL RAIL ASSEMBLY REMOVAL AND INSTALLATION

Special Tools

EN-51146 Fuel Injector Removal/ Installation Kit

EN-51146-100 Adapter Plate

EN-51146-150 Injector Remover/Installer Adapters

Equivalent regional tools:Special Tools (Diagnostic Tools) Special Tools (Repair Tools)

Removal Procedure

WARNING: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

WARNING: Diesel/Gasoline Vapors Warning WARNING: Safety Goggles and Fuel Warning

CAUTION: When working on the fuel rail and fuel injectors, always maintain a clean work surface. Failure to maintain a clean work surface can result in contaminant on the injector seals and cause leaks.

1. Remove Ignition Coil Replacement

2. Remove Fuel Feed Intermediate Pipe Replacement

Fig. 156: Fuel Injection Fuel Rail Wiring Harness And Fuel Rail Bolts Courtesy of GENERAL MOTORS COMPANY

3. Disconnect Fuel Injection Fuel Rail Wiring Harness(1)

NOTE: The fuel rail bolts remain with decoupling elements and retainer at the fuel rail assembly.

4. Loosen the 4 fuel rail bolts (2) from the cylinder head completely, but do not remove the bolts.

Fig. 157: fuel injector cylinder 1

Courtesy of GENERAL MOTORS COMPANY

NOTE: Never loosen both bolts at the same time. Failure to follow this caution could cause leaks or malfunction after installation.

NOTE: Pay attention, that the bolt does not fall into the cylinder head slot.

5. Remove the fuel injector bolt (1) from the fuel injector cylinder 1 (2) at the rail side.

Fig. 158: Demounting Screw And Support Courtesy of GENERAL MOTORS COMPANY

6. Install the EN-51146 - 1-150 demounting screw to the EN-51146-1-1 support (1) and tighten to 7N.m (62 lb in).

Fig. 159: Support And Cylinder 1 Fuel Injector Courtesy of GENERAL MOTORS COMPANY

7. Install the EN-51146-1-1 support (1) to the fuel injector cylinder 1 (2) and tighten to 5 N.m (44 lb in).

Fig. 160: Fuel Injector Cylinder

Courtesy of GENERAL MOTORS COMPANY

8. Remove the fuel injector bolt (1) from the fuel injector cylinder 1 (2).

9. Install the EN-51146-1-6 demounting screw or EN-51146-150 demounting screw to the EN-51146-1-1

support and tighten to 7 N.m (62 lb in).

Fig. 161: Support And Cylinder 1 Fuel Injector Courtesy of GENERAL MOTORS COMPANY

10. Install the EN-51146-1-1 support (1) to the fuel injector cylinder 1 (2) and tighten to 5 N.m (44 lb in).

11. Repeat the steps 5 - 10 for the other 3 injectors.

Fig. 162: Fuel Rail Bolts

Courtesy of GENERAL MOTORS COMPANY

NOTE: The fuel rail bolts remain with decoupling elements and retainer at the fuel rail assembly.

12. Loosen the 4 fuel rail bolts (1) completely from the cylinder head, but do not remove the bolts.

Fig. 163: Plates, Supports And Bolts

Courtesy of GENERAL MOTORS COMPANY

NOTE: Mind the arrow on the EN-51146-100 plate. The arrow must show in driving direction.

13. Install the EN-51146-100 plate (2) to the 8 EN-51146-1-1 supports (4).

14. Install the 8 plate bolts (3).

15. Tighten the 8 plate bolts (3) and counterhold with a wrench (1) at the EN-51146-1-1 supports (4).

Fig. 164: Slide Hammers And Plate

Courtesy of GENERAL MOTORS COMPANY

16. Install the 2 EN-51146-1-3 sliding hammers (1) to the EN-51146-1-2 plate (2).

Fig. 165: Removing Injectors

Courtesy of GENERAL MOTORS COMPANY

NOTE: Ensure that the fuel injectors do not become tilted. Failure to follow this caution can tilt or bend the injectors and could cause leaks or malfunction after installation.

17. Use the 2 EN-51146-1-3 sliding hammers at first equally to remove the fuel injector rail assembly, if necessary apply additional force to either side as necessary to release the rail evenly.

18. Ensure that the angle of the 2 EN-51146-1-3 sliding hammers (1) accord to the angle of the fuel injectors (2), while removing.

CAUTION: After removal of the fuel injection fuel rail assembly, check the

completeness of the assembly. Check that no decoupling elements, fuel rail bolts or fuel injector seals remain near the fuel injector bores on the cylinder head. Failure to perform this can result in poor engine performance or engine damage.

19. Remove the fuel injector rail assembly.

Fig. 166: Plate Installed In Vise

Courtesy of GENERAL MOTORS COMPANY

CAUTION: After removing the fuel rail and injector assembly, do not allow the weight of the assembly to rest on the fuel injectors. Always position the assembly on a clean work surface with the fuel injectors on top. Failure to follow this caution could cause leaks or malfunction after installation.

20. Install the EN-51146-1-2 plate (1) with the fuel injector assembly to a bench vise (2).

Fig. 167: Calibration Tools And Fuel Injectors Courtesy of GENERAL MOTORS COMPANY

NOTE: The EN-51146-2-5 calibration tools are also used to protect the fuel injectors.

21. Install the 4 EN-51146-2-5 calibration tools (2) rotary to the fuel injectors (1), as shown in the graphic.

22. Cover the fuel injector bores at the cylinder head, to prevent for dirt.

23. Remove the 2 EN-51146-1-3 sliding hammers.

24. Remove the 4 EN-51146-2-5 calibration tools.

Fig. 168: Combustion Seals And Stylus Courtesy of GENERAL MOTORS COMPANY

CAUTION: Always use the stylus from the EN-51146 fuel injector kit. Never use a metal tool in place of the stylus. Use of another tool can damage the fuel injector and may cause a leak.

25. Remove the 2 combustion seals (2) each fuel injector, use EN-51146-2-1 stylus (1).

26. Inspect all fuel injectors for damage.

Installation Procedure

1. Clean and inspect the fuel injectors and the fuel injector rail. Do not remove the fuel injector from the fuel rail. Refer to Fuel Injector and Fuel Injector Bore Cleaning and Inspection .

Fig. 169: Combustion Fuel Injector Seal And Long Mounting Sleeve Courtesy of GENERAL MOTORS COMPANY

2. Install a NEW combustion fuel injector seal (1) to the EN-51146-2-2 mounting sleeve-long (2).

Fig. 170: Installing Combustion Seals

Courtesy of GENERAL MOTORS COMPANY

3. Use the EN-51146-2-6-1 slider outside (1) to push down the combustion fuel injector seal (2) on the

EN-51146-2-2 mounting sleeve-long (3).

Fig. 171: Installing Combustion Seals

Courtesy of GENERAL MOTORS COMPANY

4. Push the combustion fuel injector seal (2) over the EN-51146-2-2 mounting sleeve-long, use the

EN-51146-2-6-1 slider outside (1) to the fuel injector (3).

5. Remove the EN-51146-2-2 mounting sleeve-long with the EN-51146-2-1 stylus from the

EN-51146-2-6-1 slider outside.

6. Install a NEW combustion fuel injector seal to the EN-51146-2-3 mounting sleeve-short.

7. Use the EN-51146-2-6-1 slider outside to push down the combustion fuel injector seal on the

EN-51146-2-2 mounting sleeve-short.

8. Push the combustion fuel injector seal over the EN-51146-2-3 mounting sleeve-short, use the

EN-51146-2-6-1 slider outside to the fuel injector.

9. Remove the EN-51146-2-3 mounting sleeve-short with the EN-51146-2-1 stylus from the

EN-51146-2-6-1 slider outside.

Fig. 172: Fuel Injector Limiter

Courtesy of GENERAL MOTORS COMPANY

10. Before using the EN-51146-2-4 pre-sizing tool (1), check if the fuel injector limiter (2) is in the right position.

Fig. 173: Pre-Sizing Tool And Fuel Injector Courtesy of GENERAL MOTORS COMPANY

NOTE: First form the combustion fuel injector seals a bit with finger and thumb.

11. Push the EN-51146-2-4 pre-sizing tool (1) over the fuel injector (2).

Fig. 174: Pre-Sizing Tool

Courtesy of GENERAL MOTORS COMPANY

12. Tighten the nut (2) and counterhold at the spanner flat of the EN-51146-2-4 pre-sizing tool thread (1) until the measure (a) of 4.5 mm (0.177 in) is reached.

13. Loosen the nut (2) of the EN-51146-2-4 pre-sizing tool.

Fig. 175: Take Off Chassis And Pre-Sizing Tool Courtesy of GENERAL MOTORS COMPANY

14. Install the EN-51146-2-4-7 take off chassis (2) to the EN-51146-2-4 pre-sizing tool (3).

15. Install the EN-51146-2-4-6 screw M10 (1) to the EN-51146-2-4-7 take off chassis (2), and tighten until the EN-51146-2-4 pre-sizing tool (3) is loosened.

Fig. 176: Calibration Tool And Fuel Injector Courtesy of GENERAL MOTORS COMPANY

16. Install the EN-51146-2-5 calibration tool (2) rotary to the fuel injector (1), as shown in the graphic.

17. Remove the EN-51146-2-5 calibration tool from the fuel injector.

Fig. 177: Installing Seal

Courtesy of GENERAL MOTORS COMPANY

WARNING: The fuel injector seals must fit properly in the relative groove. Overlapping of the fuel injector seals with the external surface of the injector must be avoided. If the seals are installed incorrectly, it could cause leaks and risk of injury.

18. Check the combustion fuel injector seals (2 seals each fuel injector) for correct seat: The seal must not be too large, buckled or corrugated (1).

The seal must be fixed tight and accurate (2).

19. If the seals are installed not correctly, repeat the steps 27 - 29 of the removal procedure and the steps 1 - 19 of the installation procedure.

Fig. 178: Calibration Tools And Fuel Injectors Courtesy of GENERAL MOTORS COMPANY

20. Install the 4 EN-51146-2-5 calibration tools (2) rotary to the fuel injectors (1).

21. Remove the fuel injector assembly with the EN-51146-100 plate from the bench vise.

Fig. 179: Plate, Bolts And Supports

Courtesy of GENERAL MOTORS COMPANY

22. Remove the 8 plate bolts (1) and remove EN-51146-100 plate (2), counterhold with a wrench (4) at the

EN-51146-1-1 supports (3).

Fig. 180: Support, Fuel Injector And Bolt Courtesy of GENERAL MOTORS COMPANY

NOTE: Never loosen both EN-51146-1-1 supports at the same time. Failure to follow this caution could cause leaks or malfunction after installation. It is only possible, when the fuel injector will be replaced.

23. Remove one EN-51146-1-1 support (2) from the fuel injector (3).

NOTE: DO NOT reuse the old fuel injector bolt.

24. Apply thread lock agent to the NEW fuel injector bolt (1).

25. Install NEW fuel injector bolt to the fuel injector and tighten to 5 N.m (44 lb in).

Fig. 181: Support, Fuel Injector And Bolt Courtesy of GENERAL MOTORS COMPANY

26. Remove the EN-51146-1-1 support (1) from the fuel injector (3).

NOTE: DO NOT reuse the old fuel injector bolt.

27. Apply thread lock agent to the NEW fuel injector bolt (2).

28. Install a NEW fuel injector bolt to the fuel injector and tighten to 5 N.m (44 lb in).

29. Repeat the steps 22 - 27 for the other 3 injectors.

30. Clean the fuel injector bores at the cylinder head. Refer to Fuel Injector and Fuel Injector Bore Cleaning and Inspection .

Fig. 182: Fuel Injector Rail Assembly Bolts, Decoupling Elements And Retainer Courtesy of GENERAL MOTORS COMPANY

31. Inspect the fuel injector rail assembly:

Check the 4 fuel injector for damage.

Check the 8 fuel injector seals for correct seat.

Check if all bolts (3) with decoupling elements (1) and retainer (2) are complete.

32. Remove the 4 EN-51146-2-5 calibration tools from the fuel injector.

Fig. 183: Fuel Rail Assembly

Courtesy of GENERAL MOTORS COMPANY

CAUTION: During the installation of the fuel rail and injector assembly, ensure that the fuel injectors are positioned straight into the injector opening. Failure to follow this caution can tilt or bend the injectors and could cause leaks or malfunction after installation.

33. Install carefully the fuel rail assembly (1).

34. Push the fuel injectors slightly in their seats.

Fig. 184: Fuel Rail Bolt Tightening Sequence Courtesy of GENERAL MOTORS COMPANY

35. Tighten the 8 fuel rail bolts in the sequence as shown to 10 N.m (89 lb in).

Fig. 185: Fuel Injection Fuel Rail Wiring Harness And Fuel Rail Bolts Courtesy of GENERAL MOTORS COMPANY

36. Connect Fuel Injection Fuel Rail Wiring Harness(1)

37. Install Fuel Feed Intermediate Pipe Replacement

38. Install Ignition Coil Replacement

39. After replacement of any components of the fuel injection systems, use a scan tool to reset functions. Refer to Control Module References .

WARNING: Fuel escapes - observe safety measures and national legislation. Failure to comply could result in personal injury.

NOTE: Ensure that all work at the engine is finished.

40. Perform a fuel rail assembly leak test.

1. Start the engine.

2. Check the fuel system for leaks.

FUEL INJECTION FUEL RAIL FUEL PRESSURE SENSOR REPLACEMENT

Removal Procedure

WARNING: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

WARNING: Fuel/gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

WARNING: Wear safety glasses in order to avoid eye damage.

CAUTION: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution .

1. Relieve the fuel system pressure. Fuel Pressure Relief

2. Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection

3. Remove Intake Manifold Cover - Intake Manifold Cover Replacement

Fig. 186: Fuel Injection Fuel Rail Assembly, Fuel Injection Fuel Rail Pressure Sensor And Electrical Connector

Courtesy of GENERAL MOTORS COMPANY

4. Disconnect the electrical connector (2).

NOTE: Do NOT apply force to the plastic housing of the fuel injection fuel rail fuel pressure sensor. ONLY apply force to the attached hexagon.

Some fuel may leak from the fuel injection fuel rail orifice after the sensor is removed. Dry the area around the orifice using a lint free cloth.

After removal, the area around the fuel injection fuel rail sealing surface should be inspected. The surface should be free of fuel, dirt, debris, and burrs.

5. Remove and DISCARD the fuel injection fuel rail fuel pressure sensor (1).

Installation Procedure

Fig. 187: Fuel Injection Fuel Rail Assembly, Fuel Injection Fuel Rail Pressure Sensor And Electrical Connector

Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Component Fastener Tightening Caution .

NOTE: Do NOT apply force to the plastic housing of the fuel injection fuel rail fuel pressure sensor. ONLY apply force to the attached hexagon.

BEFORE installation of the fuel injection fuel rail fuel pressure sensor, the fuel injection fuel rail threads MUST be clean and free of any fuel or the sensor will NOT seal properly.

1. To install the NEW fuel injection fuel rail fuel pressure sensor (1) properly, perform the following steps:

1. Lubricate the sensor threads and sealing surface with one drop of clean engine oil.

2. Install the sensor and hand tighten.

3. Remove the sensor.

4. Re-lubricate the sensor threads and sealing surface with one drop of clean engine oil.

5. Install the sensor and tighten to 32 N.m (24 lb ft).

2. Connect the electrical connector (2).

3. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection

NOTE: If a fuel leak occurs at the fuel injection fuel rail, the fuel rail will need to be replaced.

4. Inspect for leaks using the following procedure:

1. Turn ON the ignition with the engine OFF for 2 seconds.

2. Turn OFF the ignition for 10 seconds.

3. Turn ON the ignition with the engine OFF.

4. Inspect for fuel leaks.

5. Install Intake Manifold Cover Intake Manifold Cover Replacement

6. When the replacement is completed, use a scan tool to perform the appropriate reset functions. Control Module References

FUEL PRESSURE SENSOR REPLACEMENT

Removal Procedure

WARNING: Diesel/Gasoline Vapors Warning WARNING: Safety Goggles and Fuel Warning

1. Relieve the fuel system pressure. Fuel Pressure Relief

2. Remove Underbody Front Air Deflector Replacement - Left Side

Fig. 188: Fuel Pressure Sensor, Seal Ring And Electrical Connector Courtesy of GENERAL MOTORS COMPANY

3. Disconnect the electrical connector.(1)

4. Place a drain pan under the vehicle.

5. Remove Fuel Pressure Sensor(2)

6. Remove Seal Ring(3) and DISCARD

Installation Procedure

Fig. 189: Fuel Pressure Sensor, Seal Ring And Electrical Connector Courtesy of GENERAL MOTORS COMPANY

1. Install a NEW seal.(3)

CAUTION: Component Fastener Tightening Caution

2. Install Fuel Pressure Sensor (2) and tighten 15 N.m (11 lb ft)

3. Connect the electrical connector.(1)

4. Remove the drain pan.

5. Install Underbody Front Air Deflector Replacement - Left Side

6. Cycle the ignition to run the fuel pump and check for fuel leaks.

FUEL INJECTION PUMP REPLACEMENT

Special Tools

BO-38185 Hose Clamp Pliers

EN-51365 High Pressure Fuel Pump Installation Alignment Gauge

Equivalent regional tools:Special Tools (Diagnostic Tools) Special Tools (Repair Tools)

Removal Procedure

WARNING: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

WARNING: Refer to Diesel/Gasoline Vapors Warning . WARNING: Refer to Safety Goggles and Fuel Warning .

1. Relieve the fuel system pressure. Fuel Pressure Relief

2. Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection

3. Drain the cooling system. Cooling System Draining and Filling

4. Remove Air Inlet Grille Panel Air Inlet Grille Panel Replacement

5. Remove Intake Manifold Cover Intake Manifold Cover Replacement

6. Remove Air Cleaner Outlet Duct Air Cleaner Outlet Duct Replacement

Fig. 190: Air Cleaner Resonator Bracket And Bolt Courtesy of GENERAL MOTORS COMPANY

7. Remove the engine wiring harness clip (1) from the bracket.

8. Remove the air cleaner resonator bracket bolt (2).

9. Remove the air cleaner resonator bracket (3).

Fig. 191: Fuel Feed Front Pipe Bracket And Nut Courtesy of GENERAL MOTORS COMPANY

10. Remove the fuel feed front pipe bracket nut (1).

11. Remove the fuel feed front pipe bracket (2) from the stud.

12. Disconnect the fuel feed front pipe (3) from the fuel pump and reposition pipe and bracket as necessary.

Fuel Feed Front Pipe Replacement

Fig. 192: Fuel Feed Intermediate Pipe Courtesy of GENERAL MOTORS COMPANY

NOTE: High pressure fuel feed pipes are one time use only. ALWAYS install a NEW high pressure fuel feed pipe if the pipe is removed OR the fittings are loosened.

13. Remove and DISCARD the fuel feed intermediate pipe. Fuel Feed Intermediate Pipe Replacement

14. Close all open connections with the EN-6015 plugs.

Fig. 193: Heater Water Auxiliary Pump Hose And Clip Courtesy of GENERAL MOTORS COMPANY

15. Use the BO-38185 pliers to disengage the heater water auxiliary pump hose clamp (1).

16. Remove the heater water auxiliary pump hose (2) from the water outlet.

17. Remove the heater water auxiliary pump hose (2) from the clip (3) and reposition the hose as necessary.

Fig. 194: Electrical Connector

Courtesy of GENERAL MOTORS COMPANY

18. Disconnect the electrical connector (1).

Fig. 195: Engine Wiring Harness Ground Bolt And Harness Clips Courtesy of GENERAL MOTORS COMPANY

19. Remove the engine wiring harness ground bolt (1).

20. Remove the engine wiring harness clips (2) from the engine wiring harness bracket.

NOTE: Disconnect any engine wiring harness electrical connectors from sensors, including the fuel pump, as necessary, to provide enough space to work in the area around the fuel pump.

21. Reposition the engine wiring harness (3) as necessary.

Fig. 196: Engine Wiring Harness Bracketand Bolts Courtesy of GENERAL MOTORS COMPANY

22. Remove the engine wiring harness bracket bolts (1).

23. Remove the engine wiring harness bracket (2).

Fig. 197: Fuel Pump Insulator

Courtesy of GENERAL MOTORS COMPANY

24. Remove the fuel pump insulator (1).

Fig. 198: Fuel Pump Bolts

Courtesy of GENERAL MOTORS COMPANY

CAUTION: Alternately loosen the fuel pump bolts one turn at a time until the pump is fully disengaged from fuel pump lifter follower. Trying to remove the pump bolts without even side-to-side loosening may result in pump plunger damage

25. Remove and DISCARD the fuel pump bolts (1).

NOTE: Ensure that during removal of the fuel pump that the valve lifter follower does NOT fall apart.

26. Remove the fuel pump (2).

NOTE: The valve lifter follower MAY remain in the cylinder head bore after removing the fuel pump.

If the valve lifter follower does NOT pull out of the cylinder head bore with the fuel pump, then remove it afterwards.

27. Remove the valve lifter follower (3).

Fig. 199: Fuel Pump Housing Seal

Courtesy of GENERAL MOTORS COMPANY

28. Remove and DISCARD the fuel pump housing seal (1).

Installation Procedure

1. Before continuing, lubricate the cylinder head bore with clean engine oil.

Fig. 200: Valve Lifter Follower

Courtesy of GENERAL MOTORS COMPANY

2. Lubricate the valve lifter follower (1) with clean engine oil and install it into the cylinder head bore.

NOTE: The camshaft MUST be at the base circle position before the fuel pump is installed.

At the base circle position, the EN-51365 alignment gauge will sit flush with the cylinder head.

3. Install the EN-51365 alignment gauge (2) and turn the crankshaft until the camshaft lobe is at the base circle position.

4. Remove the EN-51365 alignment gauge (2) and valve lifter follower (1).

Fig. 201: Fuel Pump Housing Seal

Courtesy of GENERAL MOTORS COMPANY

5. Lubricate the NEW fuel pump housing seal (1) with clean engine oil and install it on the fuel pump.

Fig. 202: Fuel Pump Bolts And Fuel Pump Bolt Retainers Courtesy of GENERAL MOTORS COMPANY

CAUTION: This vehicle is equipped with torque-to-yield or single use fasteners.

Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

NOTE: ALWAYS make sure the fuel pump bolt retainers are present before installing the fuel pump bolts.

If ANY fuel pump bolt retainers are missing or NOT suitable for reuse, replace the retainers as necessary.

6. Install the NEW fuel pump bolts (1) through the fuel pump bolt retainers (2).

Fig. 203: Valve Lifter Follower

Courtesy of GENERAL MOTORS COMPANY

7. Lubricate the valve lifter follower (1) again with clean engine oil, if necessary, and install it into the cylinder head bore.

8. Install the fuel pump assembly (2) into the cylinder head and start the NEW fuel pump bolts (3) by hand.

CAUTION: Refer to Fastener Caution .

CAUTION: Alternately hand-tighten the fuel pump bolts one turn at a time until the pump is fully seated. Trying to draw down the pump without even side-to- side tightening may result in pump plunger damage.

9. Tighten the NEW fuel pump bolts (3) to 25 N.m (18 lb ft).

Fig. 204: Fuel Pump Insulator

Courtesy of GENERAL MOTORS COMPANY

10. Install the fuel pump insulator (1).

Fig. 205: Engine Wiring Harness Bracketand Bolts Courtesy of GENERAL MOTORS COMPANY

11. Position the engine wiring harness bracket (2).

12. Install the engine wiring harness bracket bolts (1) and tighten to 25 N.m (18 lb ft).

Fig. 206: Engine Wiring Harness Ground Bolt And Harness Clips Courtesy of GENERAL MOTORS COMPANY

NOTE: Connect any engine wiring harness electrical connectors to sensors, including the fuel pump, that were previously disconnected.

13. Position the engine wiring harness (3).

14. Install the engine wiring harness clips (2) in the engine wiring harness bracket.

15. Install the engine wiring harness ground bolt (1) and tighten to 10 N.m (89 lb in).

Fig. 207: Electrical Connector

Courtesy of GENERAL MOTORS COMPANY

16. Connect the electrical connector (1).

Fig. 208: Heater Water Auxiliary Pump Hose And Clip Courtesy of GENERAL MOTORS COMPANY

17. Install the heater water auxiliary pump hose (2) to the water outlet.

18. Use the BO-38185 pliers to engage the heater water auxiliary pump hose clamp (1).

19. Install the heater water auxiliary pump hose (2) in the clip (3).

20. Remove all EN-6015 plugs.

Fig. 209: Fuel Feed Intermediate Pipe Courtesy of GENERAL MOTORS COMPANY

NOTE: High pressure fuel feed pipes are one time use only. ALWAYS install a NEW high pressure fuel feed pipe if the pipe is removed OR the fittings are loosened.

21. Install the NEW fuel feed intermediate pipe. Fuel Feed Intermediate Pipe Replacement

Fig. 210: Fuel Feed Front Pipe Bracket And Nut Courtesy of GENERAL MOTORS COMPANY

22. Position fuel feed front pipe and bracket as necessary and connect the fuel feed front pipe (3) to the fuel pump. Fuel Feed Front Pipe Replacement

23. Position the fuel feed front pipe bracket (2) on the stud.

24. Install the fuel feed front pipe bracket nut (1) and tighten to 9 N.m (80 lb in).

Fig. 211: Air Cleaner Resonator Bracket And Bolt Courtesy of GENERAL MOTORS COMPANY

25. Position the air cleaner resonator bracket (3).

26. Install the air cleaner resonator bracket bolt (2) and tighten to 9 N.m (80 lb in).

27. Install the engine wiring harness clip (1) to the bracket.

28. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection

29. Inspect for leaks using the following procedure:

1. Turn ON the ignition with the engine OFF for 2 seconds.

2. Turn OFF the ignition for 10 seconds.

3. Turn ON the ignition with the engine OFF.

4. Inspect for fuel leaks.

30. Install Air Cleaner Outlet Duct Air Cleaner Outlet Duct Replacement

31. Install Intake Manifold Cover Intake Manifold Cover Replacement

32. Install Air Inlet Grille Panel Air Inlet Grille Panel Replacement

33. Fill the cooling system. Cooling System Draining and Filling

34. When the replacement is completed, use a scan tool to perform the appropriate reset functions. Control Module References

FUEL SYSTEM CLEANING

WARNING: Diesel/Gasoline Vapors Warning

The following procedure covers the disassembly and the inspection of the complete fuel supply system. If the fuel system is contaminated, the fuel system can be cleaned. You can usually determine the extent of the fuel system contamination during the disassembly.

1. Remove the fuel tank pump module. Refer to Fuel Tank Fuel Pump Module Replacement.

2. Locate the tank in a suitable work area away from any heat, any flame, or any other source of ignition.

3. Perform the following procedures:

Inspect the fuel tank pump module strainer. Replace the fuel tank pump module if the strainer is contaminated.

WARNING: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury.

NOTE: Only use oil-free compressed air to blow out the fuel pipes.

Use compressed air in order to apply air pressure to the transfer tube.

NOTE: When flushing the fuel tank, handle the fuel and water mixture as a hazardous material. Handle the fuel and water in accordance with all applicable local, state, and federal laws and regulations.

4. Flush the fuel tank with running hot water for at least five minutes. Pour the water out of the fuel pump module opening. Rock the fuel tank in order to ensure that the removal of the water from the fuel tank is complete.

5. Refer to Metal Collar Quick Connect Fitting Service in order to disconnect the fuel feed hose/pipe.

6. Use compressed air in order to apply air pressure to the fuel lines in the opposite direction from the normal fuel flow.

7. Remove the fuel rail and the fuel injectors. Refer to Fuel Injection Fuel Rail Assembly Replacement.

8. Clean and inspect the fuel injectors and the fuel rail.

Installation Procedure

Assemble the fuel system as follows:

1. Install the direct fuel injectors and the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement.

2. Install the fuel tank pump module. Refer to Fuel Tank Fuel Pump Module Replacement.

3. Refer to Metal Collar Quick Connect Fitting Service in order to connect the fuel feed hose/pipe.

FUEL FEED FRONT PIPE REPLACEMENT

Special Tools

EN-6015 Closure Plugs

Equivalent regional tools:Special Tools (Diagnostic Tools) Special Tools (Repair Tools)

Removal Procedure

1. Relieve the fuel system pressure. Fuel Pressure Relief

2. Disconnect Battery Negative Cable Disconnection and Connection

3. Remove Air Cleaner Outlet Duct Replacement

Fig. 212: Fuel Feed Pipe, Fuel Feed Front Pipe And Retainer Courtesy of GENERAL MOTORS COMPANY

4. Remove Fuel Feed Front Pipe (2) @Retainer(3)

5. Disconnect Fuel Feed Front Pipe(2)@Fuel Feed Pipe(1)Metal Collar Quick Connect Fitting Service

6. Close all open connections with the EN-6015 plugs.

Fig. 213: Fuel Feed Front Pipe And Fuel Injection Pump Courtesy of GENERAL MOTORS COMPANY

7. Disconnect Fuel Feed Front Pipe(2)@Fuel Injection Pump(1)Metal Collar Quick Connect Fitting Service

8. Close all open connections with the EN-6015 plugs.

9. Remove Fuel Feed Front Pipe(2)

Installation Procedure

Fig. 214: Fuel Feed Front Pipe And Fuel Injection Pump Courtesy of GENERAL MOTORS COMPANY

1. Install Fuel Feed Front Pipe (2)

2. Remove all EN-6015 plugs from the connections.

3. Connect Fuel Feed Front Pipe (2) @Fuel Injection Pump(1) Metal Collar Quick Connect Fitting Service

Fig. 215: Fuel Feed Pipe, Fuel Feed Front Pipe And Retainer Courtesy of GENERAL MOTORS COMPANY

4. Remove all EN-6015 plugs from the connections.

5. Connect Fuel Feed Front Pipe(2)@Fuel Feed Pipe(1)Metal Collar Quick Connect Fitting Service

6. Install Fuel Feed Front Pipe(2)@Retainer(3)

7. Install Air Cleaner Outlet Duct Replacement

8. Connect Battery Negative Cable Disconnection and Connection

9. Cycle the ignition to run the fuel pump and check for fuel leaks.

FUEL FEED INTERMEDIATE PIPE REPLACEMENT

Removal Procedure

WARNING: Refer to Diesel/Gasoline Vapors Warning . WARNING: Refer to Safety Goggles and Fuel Warning .

1. Relieve the fuel system pressure. Fuel Pressure Relief

2. Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection

3. Remove Intake Manifold Cover Intake Manifold Cover Replacement

4. Remove Air Cleaner Outlet Duct Air Cleaner Outlet Duct Replacement

Fig. 216: Air Cleaner Resonator Bracket, Bolt And Wiring Harness Clip Courtesy of GENERAL MOTORS COMPANY

5. Unclip Wiring Harness Clip (1)

6. Remove the air cleaner resonator bracket bolt (1).

7. Remove the air cleaner resonator bracket (2).

Fig. 217: Fuel Feed Intermediate Pipe, Bolt And Nuts Courtesy of GENERAL MOTORS COMPANY

NOTE: Lay a lint-free cloth under the fuel feed intermediate pipe to absorb any excess fuel spillage.

8. Remove the fuel feed intermediate pipe bolt (1).

9. Loosen the fuel feed intermediate pipe fittings (2, 5) at the fuel injection fuel rail (3) and the fuel pump (4).

NOTE: High pressure fuel feed pipes are one time use only. ALWAYS install a

NEW high pressure fuel feed pipe if the pipe is removed OR the fittings are loosened.

10. Remove and DISCARD the fuel feed intermediate pipe (6).

Installation Procedure

Fig. 218: Fuel Feed Intermediate Pipe, Bolt And Nuts Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Component Fastener Tightening Caution .

NOTE: High pressure fuel feed pipes are one time use only. ALWAYS install a NEW high pressure fuel feed pipe if the pipe is removed OR the fittings are loosened.

1. To install the NEW fuel feed intermediate pipe (6) perform the following steps:

1. Hand tighten the fuel feed intermediate pipe fitting (2) to the fuel injection fuel rail (3).

2. Hand tighten the fuel feed intermediate pipe fitting (5) to the fuel pump (4).

3. Tighten the fuel feed intermediate pipe fittings (2, 5) to 30 N.m (22 lb ft).

CAUTION: Refer to Fastener Caution .

2. Install the fuel feed intermediate pipe bolt (1) and tighten to 10 N.m (89 lb in).

Fig. 219: Air Cleaner Resonator Bracket, Bolt And Wiring Harness Clip Courtesy of GENERAL MOTORS COMPANY

3. Position the air cleaner resonator bracket (2).

4. Install the air cleaner resonator bracket bolt (1) and tighten to 9 N.m (80 lb in).

5. Install Wiring Harness Clip (1)

6. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection

WARNING: Fuel escapes - observe safety measures and national legislation. Failure to comply could result in personal injury.

7. Inspect for leaks using the following procedure:

1. Turn ON the ignition with the engine OFF for 2 seconds.

2. Turn OFF the ignition for 10 seconds.

3. Turn ON the ignition with the engine OFF.

4. Inspect for fuel leaks.

8. Install Air Cleaner Outlet Duct Air Cleaner Outlet Duct Replacement

9. Install Intake Manifold Cover Intake Manifold Cover Replacement

EVAPORATIVE EMISSION CANISTER REPLACEMENT

Removal Procedure

WARNING: Safety Goggles and Fuel Warning

WARNING: Fuel Vapors in Evaporative Emission Components Warning

1. Remove Evaporative Emission Canister Bracket Replacement

Fig. 220: Evaporative Emission Canister, Control Valve Hose, Electrical Connector And Retaining Tab

Courtesy of GENERAL MOTORS COMPANY

2. Disconnect the evaporative emission canister control valve hose (4). Refer to Plastic Collar Quick Connect Fitting Service.

3. Disconnect the electrical connector.(5)

4. Release the retaining tab (2) using a flat bladed tool (1) while simultaneously sliding the canister in direction of arrow.

5. Remove Evaporative Emission Canister(3)

Installation Procedure

Fig. 221: Evaporative Emission Canister, Control Valve Hose, Electrical Connector And Retaining Tab

Courtesy of GENERAL MOTORS COMPANY

1. Install Evaporative Emission Canister(3) -

2. Slide the evaporative emission canister (3) against the direction of arrow until the retaining tab (2) is locked.

3. Connect the electrical connector.(5)

4. Connect the evaporative emission canister control valve hose (4). Refer to Plastic Collar Quick Connect Fitting Service.

5. Install Evaporative Emission Canister Bracket Replacement

EVAPORATIVE EMISSION CANISTER BRACKET REPLACEMENT

Special Tools

EN-6015 Closure Plugs

Equivalent regional tools:Special Tools (Diagnostic Tools) Special Tools (Repair Tools)

Removal Procedure

WARNING: Safety Goggles and Fuel Warning WARNING: Safety Goggles and Fuel Warning

1. Disconnect Battery Negative Cable Disconnection and Connection

2. Raise and support the vehicle. Lifting and Jacking the Vehicle

3. Remove Underbody Rear Air Deflector Replacement

Fig. 222: Electrical Connectors, Evaporative Emission Rear Hose, Evaporative Emission Pipe, Vacuum Leak Pump Filter Pipe And Retainer

Courtesy of GENERAL MOTORS COMPANY

4. Disconnect the electrical connector:

1. Evaporative Emission System Vacuum Leak Detection Pump (1)

2. Fuel Tank Pressure Sensor (3)

3. Fuel Tank Fuel Pump Module Wiring Harness (5).

5. Disconnect Evaporative Emission Rear Hose (6)Plastic Collar Quick Connect Fitting Service

6. Disconnect Evaporative Emission Pipe (7)Plastic Collar Quick Connect Fitting Service

7. Disconnect the evaporative emission system vacuum leak pump filter pipe (2). Refer to Plastic Collar Quick Connect Fitting Service.

8. Close all open connection with the EN-6015 plugs.

9. Remove Retainer (4)

Fig. 223: Evaporative Emission Canister Bracket And Nuts Courtesy of GENERAL MOTORS COMPANY

10. Remove the 4 evaporative emission canister bracket nuts (2).

NOTE: A second technician is required.

11. Lower the evaporative emission canister bracket (1) until the evaporative emission canister control valve wiring harness is accessible.

Fig. 224: Electrical Connector And Retainers

Courtesy of GENERAL MOTORS COMPANY

12. Disconnect the electrical connector.(2)

13. Remove Retainer(1)

14. Lay the evaporative emission canister bracket on a bench.

Disassemble Procedure

Fig. 225: Evaporative Emission Canister And Vacuum Leak Pump Components Courtesy of GENERAL MOTORS COMPANY

1. Remove Retainer(1)

2. Remove the evaporative emission system vacuum leak pump cover (4).

NOTE: Use a flat bladed tool to release the 2 retaining tabs.

3. Remove the evaporative emission system vacuum leak pump (3).

4. Remove the evaporative emission canister control valve vacuum hose (6). Refer to Plastic Collar Quick Connect Fitting Service.

5. Remove the 2 evaporative emission canister vent solenoid valve bolts (1).

6. Remove the evaporative emission canister (2) along with the evaporative emission canister vent solenoid valve (7) and the evaporative emission canister hose. Refer to Evaporative Emission Canister Replacement.

Assemble Procedure

Fig. 226: Evaporative Emission Canister And Vacuum Leak Pump Components Courtesy of GENERAL MOTORS COMPANY

1. Install the evaporative emission canister (2) along with the evaporative emission canister vent solenoid valve (7) and the evaporative emission canister hose. Refer to Evaporative Emission Canister Replacement.

CAUTION: Fastener Caution

2. Install the 2 evaporative emission canister vent solenoid valve bolts (1) and tighten to 7 N.m (62 lb in).

3. Install the evaporative emission canister control valve vacuum hose (6). Refer to Plastic Collar Quick Connect Fitting Service.

NOTE: There must be 2 noticeable click noises.

4. Install the evaporative emission system vacuum leak pump (3).

5. Install the evaporative emission system vacuum leak pump cover (4).

6. Install Retainer(5)

Installation Procedure

NOTE: A second technician is required.

1. Raise the evaporative emission canister bracket until the evaporative emission canister control valve wiring harness is accessible.

Fig. 227: Electrical Connector And Retainers Courtesy of GENERAL MOTORS COMPANY

2. Install Retainer(1)

3. Connect the electrical connector.(2)

Fig. 228: Evaporative Emission Canister Bracket And Nuts Courtesy of GENERAL MOTORS COMPANY

4. Raise the evaporative emission canister bracket (1) completely.

5. Install the 4 evaporative emission canister bracket nuts (2) and tighten to 9 N.m (80 lb in).

Fig. 229: Electrical Connectors, Evaporative Emission Rear Hose, Evaporative Emission Pipe, Vacuum Leak Pump Filter Pipe And Retainer

Courtesy of GENERAL MOTORS COMPANY

6. Install Retainer(4)

7. Remove the EN-6015 plugs from all connections.

8. Connect the evaporative emission system vacuum leak pump filter pipe (2). Refer to Plastic Collar Quick Connect Fitting Service.

9. Connect Evaporative Emission Pipe (7)Plastic Collar Quick Connect Fitting Service

10. Connect Evaporative Emission Rear Hose (6)Plastic Collar Quick Connect Fitting Service

11. Connect the electrical connector:

1. Evaporative Emission System Vacuum Leak Detection Pump (1)

2. Fuel Tank Pressure Sensor (3)

3. Fuel Tank Fuel Pump Module Wiring Harness (5).

12. Install Underbody Rear Air Deflector Replacement

13. Lower the vehicle.

14. Connect Battery Negative Cable Disconnection and Connection

EVAPORATIVE EMISSION CANISTER HOSE REPLACEMENT

Special Tools

EN-6015 Closure Plugs

Equivalent regional tools:Special Tools (Diagnostic Tools) Special Tools (Repair Tools)

Removal Procedure

WARNING: Diesel/Gasoline Vapors Warning WARNING: Safety Goggles and Fuel Warning

1. Disconnect Battery Negative Cable Disconnection and Connection

2. Lower the fuel tank, to get enough space to remove the fuel pipe. Refer to Fuel Tank Replacement.

Fig. 230: Evaporative Emission Canister Hose, Fuel Tank Fuel Pump Module And Retainer Courtesy of GENERAL MOTORS COMPANY

3. Disconnect the evaporative emission canister hose (3) from the fuel tank fuel pump module (1). Refer to

Plastic Collar Quick Connect Fitting Service.

4. Close all open connections with the EN-6015 plugs.

5. Unclip the evaporative emission canister hose (3) from the retainer (2).

Installation Procedure

Fig. 231: Evaporative Emission Canister Hose, Fuel Tank Fuel Pump Module And Retainer Courtesy of GENERAL MOTORS COMPANY

1. Install the evaporative emission canister hose (3) to the retainer (2).

2. Remove the EN-6015 plugs from all connections.

3. Connect the evaporative emission canister hose (3) to the fuel tank fuel pump module (1). Refer to Plastic Collar Quick Connect Fitting Service.

4. Install Fuel Tank Replacement

5. Connect Battery Negative Cable Disconnection and Connection

EVAPORATIVE EMISSION CANISTER CONTROL VALVE VACUUM HOSE REPLACEMENT

Fig. 232: Evaporative Emission Canister Control Valve Vacuum Hose Courtesy of GENERAL MOTORS COMPANY

EVAPORATIVE EMISSION CANISTER PURGE SOLENOID VALVE REPLACEMENT

Special Tools

EN-6015 Closure Plugs

Equivalent regional tools:Special Tools (Diagnostic Tools) Special Tools (Repair Tools)

Removal Procedure

WARNING: Safety Goggles and Fuel Warning

WARNING: Fuel Vapors in Evaporative Emission Components Warning

1. Disconnect Battery Negative Cable Disconnection and Connection

2. Remove Air Cleaner Outlet Duct Replacement

Fig. 233: Evaporative Emission Pipe, Evaporative Emission Canister Purge Solenoid Valve, Bolt And Electrical Connector

Courtesy of GENERAL MOTORS COMPANY

3. Disconnect the electrical connector.(1)

4. Disconnect Evaporative Emission Pipe (2)Plastic Collar Quick Connect Fitting Service

5. Close all open connection with the EN-6015 plugs.

6. Remove Evaporative Emission Canister Purge Solenoid Valve Bolt (3)

7. Remove Evaporative Emission Canister Purge Solenoid Valve (4)

Installation Procedure

Fig. 234: Evaporative Emission Pipe, Evaporative Emission Canister Purge Solenoid Valve, Bolt And Electrical Connector

Courtesy of GENERAL MOTORS COMPANY

1. Install Evaporative Emission Canister Purge Solenoid Valve (4)

CAUTION: Fastener Caution

2. Install Evaporative Emission Canister Purge Solenoid Valve Bolt (3) and tighten 10 N.m (89 lb in)

3. Remove all EN-6015 plugs.

4. Connect Evaporative Emission Pipe (2) Plastic Collar Quick Connect Fitting Service

5. Connect the electrical connector.(1)

6. Install Air Cleaner Outlet Duct Replacement

7. Connect Battery Negative Cable Disconnection and Connection

EVAPORATIVE EMISSION CANISTER VENT SOLENOID VALVE REPLACEMENT

Removal Procedure

WARNING: Safety Goggles and Fuel Warning

WARNING: Fuel Vapors in Evaporative Emission Components Warning

1. Remove Evaporative Emission Canister Bracket Replacement

Fig. 235: Evaporative Emission Canister Control Valve Vacuum Hose And Evaporative Emission Canister Vent Solenoid Valve

Courtesy of GENERAL MOTORS COMPANY

2. Disconnect the evaporative emission canister control valve vacuum hose (1) from the evaporative emission canister vent solenoid valve (2). Refer to Plastic Collar Quick Connect Fitting Service.

3. Disconnect the evaporative emission canister hose (3) from the evaporative emission canister vent solenoid valve (2). Refer to Plastic Collar Quick Connect Fitting Service.

Fig. 236: Evaporative Emission Canister Vent Solenoid Valve, Canister Bracket And Bolts Courtesy of GENERAL MOTORS COMPANY

4. Remove the 2 evaporative emission canister vent solenoid valve bolts (2).

5. Remove the evaporative emission canister vent solenoid valve (1) from the evaporative emission canister bracket (3).

Installation Procedure

Fig. 237: Evaporative Emission Canister Vent Solenoid Valve, Canister Bracket And Bolts Courtesy of GENERAL MOTORS COMPANY

1. Install the evaporative emission canister vent solenoid valve (1) to the evaporative emission canister bracket (3).

CAUTION: Fastener Caution

2. Install the 2 evaporative emission canister vent solenoid valve bolts (2) and tighten to 7 N.m (62 lb in).

Fig. 238: Evaporative Emission Canister Control Valve Vacuum Hose And Evaporative Emission Canister Vent Solenoid Valve

Courtesy of GENERAL MOTORS COMPANY

3. Connect the evaporative emission canister hose (3) to the evaporative emission canister vent solenoid valve (2). Refer to Plastic Collar Quick Connect Fitting Service.

4. Connect the evaporative emission canister control valve vacuum hose (1) to the evaporative emission canister vent solenoid valve (2). Refer to Plastic Collar Quick Connect Fitting Service.

5. Install Evaporative Emission Canister Bracket Replacement

EVAPORATIVE EMISSION PIPE REPLACEMENT

Special Tools

EN-6015 Closure Plugs

Equivalent regional tools:Special Tools (Diagnostic Tools) Special Tools (Repair Tools)

Removal Procedure

WARNING: Ensure all High Voltage safety procedures are followed. Failure to follow the procedure exactly as written may result in serious injury or death.

WARNING: Fuel Vapors in Evaporative Emission Components Warning WARNING: Safety Goggles and Fuel Warning

1. Disconnect Battery Negative Cable Battery Negative Cable Disconnection and Connection

2. Remove Air Cleaner Outlet Duct Air Cleaner Outlet Duct Replacement

Fig. 239: Evaporative Emission Pipe And Evaporative Emission Canister Purge Solenoid Valve Courtesy of GENERAL MOTORS COMPANY

3. Disconnect Evaporative Emission Pipe (1)@Evaporative Emission Canister Purge Solenoid Valve(3)

Plastic Collar Quick Connect Fitting Service

4. Close all open connections with the EN-6015 plugs.

5. Open Retainer(2)

6. Remove Evaporative Emission Pipe(1)@Retainer (2)

7. Raise and support the vehicle. Lifting and Jacking the Vehicle

8. Remove Drivetrain and Front Suspension Cradle Drivetrain and Front Suspension Cradle Replacement

Fig. 240: Evaporative Emission Pipe And Retainers Courtesy of GENERAL MOTORS COMPANY

9. Open the 2 retainers (1).

10. Remove Evaporative Emission Pipe (2) @Retainer (1)

11. Remove Rear Axle Rear Axle Replacement

12. Remove Floor Panel Number 4 Cross Bar Floor Panel Number 4 Cross Bar Replacement

Fig. 241: Drive Motor Generator Control Module Cooling Outlet Hose Courtesy of GENERAL MOTORS COMPANY

13. Remove Drive Motor Generator Control Module Cooling Outlet Hose(4) Drive Motor Generator Control Module Cooling Outlet Hose Replacement (Underbody Line) Drive Motor Generator Control Module Cooling Outlet Hose Replacement (Underbody Line to Traction Power Inverter Module Inlet)

14. Open the retainer (3).

15. Remove Evaporative Emission Pipe (1) @Retainer (3)

16. Disconnect Evaporative Emission Pipe(1)@Evaporative Emission Canister(2) Plastic Collar Quick Connect Fitting Service

17. Close all open connections with the EN-6015 plugs.

Fig. 242: Evaporative Emission Pipe And Retainers Courtesy of GENERAL MOTORS COMPANY

18. Open the 5 retainers (1).

19. Remove Evaporative Emission Pipe (2) @Retainer (1)

NOTE: Manipulate the line removing the rear first to remove from the vehicle.

20. Remove the evaporative emission pipe (2) from the vehicle.

Installation Procedure

Fig. 243: Bumper

Courtesy of GENERAL MOTORS COMPANY

1. If replacing the evaporative emissions pipe with a new pipe, position the new bumper (1) on the new replacement pipe, after installation, as shown. If the old pipe is being reinstalled, position a new bumper

(1) on the existing pipe, after installation, as shown.

Fig. 244: Evaporative Emission Pipe Sleeve Courtesy of GENERAL MOTORS COMPANY

NOTE: Check sleeve for proper position after pipe installation.

2. If replacing the evaporative emissions pipe with a new pipe and the new pipe does not have a sleeve (1) on it, transfer the sleeve (1) from the old pipe to the new one.

Fig. 245: Evaporative Emission Pipe And Retainers Courtesy of GENERAL MOTORS COMPANY

3. Install the evaporative emission pipe (2) to the vehicle.

4. Install Evaporative Emission Pipe(2)@Retainer(1)

5. Close the 5 retainers (1).

Fig. 246: Drive Motor Generator Control Module Cooling Outlet Hose Courtesy of GENERAL MOTORS COMPANY

6. Remove all EN-6015 plugs from the connections.

7. Connect Evaporative Emission Pipe (1) @Evaporative Emission Canister(2)Plastic Collar Quick Connect Fitting Service

8. Install Drive Motor Generator Control Module Cooling Outlet Hose(4)Drive Motor Generator Control

Module Cooling Outlet Hose Replacement (Underbody Line) Drive Motor Generator Control Module Cooling Outlet Hose Replacement (Underbody Line to Traction Power Inverter Module Inlet)

9. Install Evaporative Emission Pipe (1) @Retainer (3)

10. Close the retainer (3).

11. Install Floor Panel Number 4 Cross Bar Floor Panel Number 4 Cross Bar Replacement

12. Install Rear Axle Rear Axle Replacement

Fig. 247: Evaporative Emission Pipe And Retainers Courtesy of GENERAL MOTORS COMPANY

NOTE: Inspect bulkhead cross car brake line and retainers as required after line installation.

13. Install Evaporative Emission Pipe(2)@Retainer(1)

14. Close the 2 retainers (31).

15. Install Drivetrain and Front Suspension Cradle Drivetrain and Front Suspension Cradle Replacement

16. Lower the vehicle.

Fig. 248: Evaporative Emission Pipe And Evaporative Emission Canister Purge Solenoid Valve Courtesy of GENERAL MOTORS COMPANY

17. Install Evaporative Emission Pipe(1)@Retainer(2)

18. Close Retainer(2)

19. Remove all EN-6015 plugs from the connections.

20. Connect Evaporative Emission Pipe(1)@Evaporative Emission Canister Purge Solenoid Valve(3) Plastic Collar Quick Connect Fitting Service

21. Install Air Cleaner Outlet Duct Air Cleaner Outlet Duct Replacement

22. Connect Battery Negative Cable Battery Negative Cable Disconnection and Connection

EVAPORATIVE EMISSION REAR HOSE REPLACEMENT

Special Tools

EN-6015 Closure Plugs

Equivalent regional tools:Special Tools (Diagnostic Tools) Special Tools (Repair Tools)

Removal Procedure

WARNING: Diesel/Gasoline Vapors Warning WARNING: Safety Goggles and Fuel Warning

1. Disconnect Battery Negative Cable Disconnection and Connection

2. Lower the fuel tank, to get enough space to remove the evaporative emission pipe. Refer to Fuel Tank Replacement.

Fig. 249: Evaporative Emission Rear Hose And Fuel Tank Fuel Pump Module Courtesy of GENERAL MOTORS COMPANY

3. Disconnect Evaporative Emission Rear Hose(2)@Fuel Tank Fuel Pump Module(1)Plastic Collar Quick Connect Fitting Service

4. Close all open connections with the EN-6015 plugs.

Installation Procedure

Fig. 250: Evaporative Emission Rear Hose And Fuel Tank Fuel Pump Module Courtesy of GENERAL MOTORS COMPANY

1. Remove all EN-6015 plugs.

2. Connect Evaporative Emission Rear Hose(2)@Fuel Tank Fuel Pump Module(1) Plastic Collar Quick Connect Fitting Service

3. Install Fuel Tank Replacement

4. Connect Battery Negative Cable Disconnection and Connection

EVAPORATIVE EMISSION SYSTEM VACUUM LEAK PUMP SHIELD REPLACEMENT

Fig. 251: Evaporative Emission System Vacuum Leak Pump Shield Courtesy of GENERAL MOTORS COMPANY

EVAPORATIVE EMISSION CANISTER VACUUM LEAK PUMP HARNESS REPLACEMENT

Special Tools

EN-6015 Closure Plugs

Equivalent regional tools:Special Tools (Diagnostic Tools) Special Tools (Repair Tools)

Removal Procedure

WARNING: Safety Goggles and Fuel Warning

WARNING: Fuel Vapors in Evaporative Emission Components Warning

1. Disconnect Battery Negative Cable Disconnection and Connection

2. Raise and support the vehicle. Lifting and Jacking the Vehicle

3. Remove Rear Wheelhouse Liner Replacement

Fig. 252: Electrical Connectors And Wiring Harness Clips Courtesy of GENERAL MOTORS COMPANY

4. Disconnect the electrical connectors.(1)

5. Unclip Wiring Harness Clip(2, 3)

6. Remove Underbody Rear Air Deflector Replacement

Fig. 253: Wiring Harness Clips

Courtesy of GENERAL MOTORS COMPANY

7. UnclipWiring Harness Clip(1)

Fig. 254: Electrical Connectors, Evaporative Emission Rear Hose, Evaporative Emission Pipe, Vacuum Leak Pump Filter Pipe And Retainer

Courtesy of GENERAL MOTORS COMPANY

8. Disconnect the electrical connector:

1. Evaporative Emission System Vacuum Leak Detection Pump (1)

2. Fuel Tank Pressure Sensor(3)

3. Fuel Tank Fuel Pump Module Wiring Harness (5).

9. Disconnect Evaporative Emission Rear Hose (6)Plastic Collar Quick Connect Fitting Service

10. Disconnect Evaporative Emission Pipe(7) Plastic Collar Quick Connect Fitting Service

11. Disconnect the evaporative emission system vacuum leak pump filter pipe (2). Refer to Plastic Collar Quick Connect Fitting Service.

12. Close all open connection with the EN-6015 plugs.

13. Remove Retainer(4)

Fig. 255: Evaporative Emission Canister Bracket And Nuts

Courtesy of GENERAL MOTORS COMPANY

14. Remove the 4 evaporative emission canister bracket nuts (2).

15. Remove the evaporative emission canister bracket (1) and put it on a workbench.

Fig. 256: Electrical Connector And Retainers Courtesy of GENERAL MOTORS COMPANY

16. Disconnect the electrical connector.(2)

17. Remove Retainer(1)

18. Remove the evaporative emission canister vacuum leak pump wiring harness.

Installation Procedure

Fig. 257: Electrical Connector And Retainers Courtesy of GENERAL MOTORS COMPANY

1. Install the evaporative emission canister vacuum leak pump wiring harness.

2. Install Retainer

3. Connect the electrical connector.

Fig. 258: Evaporative Emission Canister Bracket And Nuts Courtesy of GENERAL MOTORS COMPANY

4. Install the evaporative emission canister bracket (1).

CAUTION: Fastener Caution

5. Install the 4 evaporative emission canister bracket nuts (2) and tighten to 9 N.m (80 lb in).

Fig. 259: Electrical Connectors, Evaporative Emission Rear Hose, Evaporative Emission Pipe, Vacuum Leak Pump Filter Pipe And Retainer

Courtesy of GENERAL MOTORS COMPANY

6. Install Retainer(4)

7. Remove the EN-6015 plugs from all connections.

8. Connect the evaporative emission system vacuum leak pump filter pipe (2). Refer to Plastic Collar Quick Connect Fitting Service.

9. Connect Evaporative Emission Pipe (7) Plastic Collar Quick Connect Fitting Service

10. Connect Evaporative Emission Rear Hose (6)Plastic Collar Quick Connect Fitting Service

11. Connect the electrical connector:

1. Evaporative Emission System Vacuum Leak Detection Pump (1)

2. Fuel Tank Pressure Sensor(3)

3. Fuel Tank Fuel Pump Module Wiring Harness (5).

Fig. 260: Wiring Harness Clips

Courtesy of GENERAL MOTORS COMPANY

12. Install Wiring Harness Clip(1)

13. Install Underbody Rear Air Deflector Replacement

Fig. 261: Electrical Connectors And Wiring Harness Clips Courtesy of GENERAL MOTORS COMPANY

14. Install Wiring Harness Clip(2, 3)

15. Connect the electrical connectors.(1)

16. Install Rear Wheelhouse Liner Replacement

17. Lower the vehicle.

18. Connect Battery Negative Cable Disconnection and Connection

EVAPORATIVE EMISSION SYSTEM VACUUM LEAK PUMP FILTER REPLACEMENT

Removal Procedure

1. Remove Fuel Tank Filler Pipe Replacement

Fig. 262: Evaporative Emission System Vacuum Leak Pump Filter, Bracket, Cable Straps And Clip Courtesy of GENERAL MOTORS COMPANY

2. Remove the 3 cable straps (1, 4).

3. Remove Clip (3)

4. Unclip the evaporative emission system vacuum leak pump filter (2) from the bracket (5).

Installation Procedure

Fig. 263: Evaporative Emission System Vacuum Leak Pump Filter, Bracket, Cable Straps And Clip Courtesy of GENERAL MOTORS COMPANY

1. Install the evaporative emission system vacuum leak pump filter (2) to the bracket (5).

2. Install Clip (3)

3. Install the 3 cable straps (1, 4).

4. Install Fuel Tank Filler Pipe Replacement

EVAPORATIVE EMISSION SYSTEM VACUUM LEAK DETECTION PUMP REPLACEMENT

Removal Procedure

WARNING: Safety Goggles and Fuel Warning

WARNING: Fuel Vapors in Evaporative Emission Components Warning

1. Disconnect Battery Negative Cable Disconnection and Connection

2. Raise and support the vehicle. Lifting and Jacking the Vehicle

3. Remove Underbody Rear Air Deflector Replacement

Fig. 264: Evaporative Emission System Vacuum Leak Pump Cover, Filter Pipe, Retainers And Electrical Connector

Courtesy of GENERAL MOTORS COMPANY

4. Remove Retainer (4)

5. Remove the evaporative emission system vacuum leak pump cover (3).

6. Disconnect the evaporative emission system vacuum leak pump filter pipe (1). Refer to Plastic Collar Quick Connect Fitting Service.

7. Disconnect the electrical connector.(2)

Fig. 265: Evaporative Emission System Vacuum Leak Pump And Retaining Tabs Courtesy of GENERAL MOTORS COMPANY

NOTE: Use a flat bladed tool to release the 2 retaining tabs (2).

8. Remove the evaporative emission system vacuum leak pump (1).

Installation Procedure

Fig. 266: Evaporative Emission System Vacuum Leak Pump And Retaining Tabs Courtesy of GENERAL MOTORS COMPANY

NOTE: There must be 2 noticeable click noises.

1. Install the evaporative emission system vacuum leak pump (1).

Fig. 267: Evaporative Emission System Vacuum Leak Pump Cover, Filter Pipe, Retainers And Electrical Connector

Courtesy of GENERAL MOTORS COMPANY

2. Connect the electrical connector.(2)

3. Connect the evaporative emission system vacuum leak pump filter pipe (1). Refer to Plastic Collar Quick Connect Fitting Service.

4. Install the evaporative emission system vacuum leak pump cover (3).

5. Install Retainer(4)

6. Lower the vehicle.

7. Install Underbody Rear Air Deflector Replacement

8. Connect Battery Negative Cable Disconnection and Connection

IGNITION COIL REPLACEMENT

Removal Procedure

1. Remove Intake Manifold Cover Intake Manifold Cover Replacement

Fig. 268: Ignition Coil Electrical Connectors Courtesy of GENERAL MOTORS COMPANY

2. Disconnect Ignition Coil Electrical Connector (1)

Fig. 269: Ignition Coils And Bolts

Courtesy of GENERAL MOTORS COMPANY

3. Remove Ignition Coil Bolt (1)

4. Remove Ignition Coil (2)

Installation Procedure

1. Inspect the inside of the ignition coil boot for a thin, even coat of dielectric grease. If there is no grease present or additional grease is necessary, continue to the next step.

2. Apply a thin coating of dielectric grease to the inside of the ignition coil boot up to a depth of 15 mm (0.60 in) from the end of the boot.

3. Remove any excess dielectric grease from around the end of the ignition coil boot and ensure there is not an excessive amount within the boot.

Fig. 270: Ignition Coils And Bolts

Courtesy of GENERAL MOTORS COMPANY

4. Install Ignition Coil (2)

CAUTION: Refer to Fastener Caution .

5. Install Ignition Coil Bolt (1) and tighten 10 N.m (89 lb in)

Fig. 271: Ignition Coil Electrical Connectors

Courtesy of GENERAL MOTORS COMPANY

6. Connect Ignition Coil Electrical Connector (1)

7. Install Intake Manifold Cover Intake Manifold Cover Replacement

SPARK PLUG INSPECTION

Spark Plug Usage

1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug.

2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions:

Spark plug fouling - Colder plug

Pre-ignition causing spark plug and/or engine damage - Hotter plug

Spark Plug Inspection

Fig. 272: Cross Sectional View Of Spark Plug

Courtesy of GENERAL MOTORS COMPANY

1. Inspect the terminal post (1) for damage.

Inspect for a bent or broken terminal post (1).

Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move.

Fig. 273: Inspecting Spark Plug For Flashover Or Carbon Tracking Soot Courtesy of GENERAL MOTORS COMPANY

2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions:

Inspect the spark plug boot for damage.

Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground.

Fig. 274: Inspecting Spark Plug Insulator Courtesy of GENERAL MOTORS COMPANY

3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4).

Fig. 275: Cutaway/Description View Of Spark Plug Courtesy of GENERAL MOTORS COMPANY

4. Inspect for evidence of improper arcing.

Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications . An excessively wide electrode gap can prevent correct spark plug operation.

Inspect for the correct spark plug torque. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack.

Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). Inspect for a broken or worn side electrode (3).

Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug.

5. A rattling sound indicates internal damage.

6. A loose center electrode (4) reduces the spark intensity.

Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. Inspect for worn or missing platinum pads on the electrodes (3, 4) If equipped.

Inspect for excessive fouling.

Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation.

Spark Plug Visual Inspection

1. Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives.

2. Carbon Fouled - Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures

Leaking fuel injectors Excessive fuel pressure

Restricted air filter element Incorrect combustion

Reduced ignition system voltage output Weak coils

Worn ignition wires

Incorrect spark plug gap

Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off.

Deposit Fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode.

SPARK PLUG REPLACEMENT

Fig. 276: Spark Plugs

Courtesy of GENERAL MOTORS COMPANY

CAMSHAFT POSITION ACTUATOR SOLENOID VALVE REPLACEMENT - INTAKE

Fig. 277: Camshaft Position Actuator Solenoid Valve - Intake Courtesy of GENERAL MOTORS COMPANY

CAMSHAFT POSITION ACTUATOR SOLENOID VALVE REPLACEMENT - EXHAUST

Fig. 278: Camshaft Position Actuator Solenoid Valve - Exhaust Courtesy of GENERAL MOTORS COMPANY

CRANKSHAFT POSITION SENSOR REPLACEMENT

Fig. 279: Crankshaft Position Sensor (FWD) Courtesy of GENERAL MOTORS COMPANY

CAMSHAFT POSITION SENSOR REPLACEMENT - INTAKE

Fig. 280: Camshaft Position Sensor - Intake Courtesy of GENERAL MOTORS COMPANY

CAMSHAFT POSITION SENSOR REPLACEMENT - EXHAUST

Fig. 281: Camshaft Position Sensor - Exhaust Courtesy of GENERAL MOTORS COMPANY

AIR CLEANER ASSEMBLY REPLACEMENT

Removal Procedure

Fig. 282: Air Cleaner Outlet Duct, Air Cleaner Assembly, Clamp And Electrical Connector Courtesy of GENERAL MOTORS COMPANY

1. Disconnect the electrical connector.(1)

2. Loosen Air Cleaner Outlet Duct Clamp (2)

3. Remove Air Cleaner Outlet Duct (3) @Air Cleaner Assembly (4)

Fig. 283: Air Cleaner Assembly

Courtesy of GENERAL MOTORS COMPANY

4. Remove Air Cleaner Assembly (1)

5. Transfer parts as necessary.

Installation Procedure

Fig. 284: Air Cleaner Assembly

Courtesy of GENERAL MOTORS COMPANY

1. Install Air Cleaner Assembly (1)

Fig. 285: Air Cleaner Outlet Duct, Air Cleaner Assembly, Clamp And Electrical Connector Courtesy of GENERAL MOTORS COMPANY

2. Install Air Cleaner Outlet Duct (3) @Air Cleaner Assembly (4)

CAUTION: Refer to:Fastener Caution

3. Air Cleaner Outlet Duct Clamp (2) - Tighten 2.5 N.m (22 lb in)

4. Connect the electrical connector.(1)

AIR CLEANER ELEMENT REPLACEMENT

Removal Procedure

Fig. 286: Air Cleaner Outlet Duct, Air Cleaner Assembly, Clamp And Electrical Connector Courtesy of GENERAL MOTORS COMPANY

1. Disconnect the electrical connector.(1)

2. Loosen Air Cleaner Outlet Duct Clamp (2)

3. Remove Air Cleaner Outlet Duct (3) @Air Cleaner Assembly (4)

Fig. 287: Air Cleaner Upper Housing, Air Cleaner Element And Bolt Courtesy of GENERAL MOTORS COMPANY

4. Remove Air Cleaner Upper Housing Bolt (1)

5. Remove Air Cleaner Upper Housing (2)

6. Remove Air Cleaner Element (3)

Installation Procedure

Fig. 288: Air Cleaner Upper Housing, Air Cleaner Element And Bolt Courtesy of GENERAL MOTORS COMPANY

1. Install Air Cleaner Element(3)

2. Install Air Cleaner Upper Housing(2)

CAUTION: Fastener Caution

3. Install Air Cleaner Upper Housing Bolt(1) and tighten 2.5 N.m (22 lb in)

Fig. 289: Air Cleaner Outlet Duct, Air Cleaner Assembly, Clamp And Electrical Connector Courtesy of GENERAL MOTORS COMPANY

4. Install Air Cleaner Outlet Duct (3)@Air Cleaner Assembly (4)

5. Air Cleaner Outlet Duct Clamp (2) - Tighten 2.5 N.m (22 lb in)

6. Connect the electrical connector.(1)

AIR CLEANER OUTLET DUCT REPLACEMENT

Removal Procedure

1. Remove Intake Manifold Cover Replacement

2. Remove Dash Upper Extension Panel Opening Cover Replacement

Fig. 290: Air Cleaner Outlet Duct Clamp Courtesy of GENERAL MOTORS COMPANY

3. Loosen Air Cleaner Outlet Duct Clamp (1, 4)

4. Remove Air Cleaner Outlet Duct Fastener (2)

5. Loosen Air Cleaner Outlet Duct Bracket Bolt (5)

6. Disconnect Positive Crankcase Ventilation Tube (3)Plastic Collar Quick Connect Fitting Service

Fig. 291: Air Cleaner Outlet Duct, Air Cleaner Assembly And Throttle Body

Courtesy of GENERAL MOTORS COMPANY

7. Remove Air Cleaner Outlet Duct (2) @Air Cleaner Assembly (3)

8. Remove Air Cleaner Outlet Duct (2) @Throttle Body (1)

Installation Procedure

Fig. 292: Air Cleaner Outlet Duct, Air Cleaner Assembly And Throttle Body Courtesy of GENERAL MOTORS COMPANY

1. Install Air Cleaner Outlet Duct(2)@Throttle Body(1)

2. Install Air Cleaner Outlet Duct(2)@Air Cleaner Assembly(3)

Fig. 293: Air Cleaner Outlet Duct Clamp Courtesy of GENERAL MOTORS COMPANY

3. Connect Positive Crankcase Ventilation Tube(3) Plastic Collar Quick Connect Fitting Service

CAUTION: Fastener Caution

NOTE: Ensure the outlet duct is fully seated to the mating surfaces before clamping. Verify that the cuff is not rolled under.

4. Air Cleaner Outlet Duct Clamp(1, 4) - Tighten 2.5 N.m (22 lb in)

5. Air Cleaner Outlet Duct Bracket Bolt(5) - Tighten 9 N.m (80 lb in)

6. Install Air Cleaner Outlet Duct Fastener (2) and tighten 9 N.m (80 lb in)

7. Install Dash Upper Extension Panel Opening Cover Replacement

8. Install Intake Manifold Cover Replacement

ACCELERATOR PEDAL REPLACEMENT

Fig. 294: Accelerator Pedal

Courtesy of GENERAL MOTORS COMPANY

FUEL LEVEL SENSOR REPLACEMENT

Removal Procedure

1. Remove Fuel Tank Fuel Pump Module Replacement

Fig. 295: Fuel Level Sensor, Fuel Pump Module, Retaining Brackets And Electrical Connector Courtesy of GENERAL MOTORS COMPANY

2. Disconnect the electrical connector.(1)

3. Push the 2 retaining brackets (3) in direction of arrows.

4. While holding the 2 retaining brackets (3) move the fuel level sensor (2) upwards and remove the fuel level sensor (2) from the fuel pump module (4).

Installation Procedure

Fig. 296: Fuel Level Sensor, Fuel Pump Module, Retaining Brackets And Electrical Connector Courtesy of GENERAL MOTORS COMPANY

NOTE: There must be 2 noticeable click noises.

1. Install the fuel level sensor (2) to the fuel pump module (4).

2. Connect the electrical connector.(1)

3. Install Fuel Tank Fuel Pump Module Replacement

FUEL PUMP POWER CONTROL MODULE REPLACEMENT

Fig. 297: Fuel Pump Power Control Module

Courtesy of GENERAL MOTORS COMPANY

HEATED OXYGEN SENSOR REPLACEMENT - SENSOR 1

Fig. 298: Heated Oxygen Sensor-Sensor 1

Courtesy of GENERAL MOTORS COMPANY

HEATED OXYGEN SENSOR REPLACEMENT - SENSOR 2

Fig. 299: Heated Oxygen Sensor-Sensor 2 Courtesy of GENERAL MOTORS COMPANY

MASS AIRFLOW SENSOR REPLACEMENT

Removal Procedure

Fig. 300: Air Cleaner Outlet Duct, Air Cleaner Assembly, Clamp And Electrical Connector Courtesy of GENERAL MOTORS COMPANY

1. Disconnect the electrical connector.(1)

2. Loosen Air Cleaner Outlet Duct Clamp(2)

3. Remove Air Cleaner Outlet Duct(3)@Air Cleaner Assembly(4)

Fig. 301: Air Cleaner Upper Housing And Bolts Courtesy of GENERAL MOTORS COMPANY

4. Remove Air Cleaner Upper Housing Bolt(1)

5. Remove Air Cleaner Upper Housing(2)

Fig. 302: Mass Airflow Sensor And Bolts Courtesy of GENERAL MOTORS COMPANY

6. Remove Mass Airflow Sensor Bolt(2)

7. Remove Mass Airflow Sensor(1)

Installation Procedure

Fig. 303: Mass Airflow Sensor And Bolts Courtesy of GENERAL MOTORS COMPANY

1. Install Mass Airflow Sensor(1)

CAUTION: Fastener Caution

2. Install Mass Airflow Sensor Bolt (2) and tighten 2.5 N.m (22 lb in)

Fig. 304: Air Cleaner Upper Housing And Bolts Courtesy of GENERAL MOTORS COMPANY

3. Install Air Cleaner Upper Housing(2)

4. Install Air Cleaner Upper Housing Bolt(1) and tighten 2.5 N.m (22 lb in)

Fig. 305: Air Cleaner Outlet Duct, Air Cleaner Assembly, Clamp And Electrical Connector Courtesy of GENERAL MOTORS COMPANY

5. Install Air Cleaner Outlet Duct(3)@Air Cleaner Assembly(4)

6. Air Cleaner Outlet Duct Clamp(2) - Tighten 2.5 N.m (22 lb in)

7. Connect the electrical connector.(1)

8. When the replacement is completed, use a scan tool to perform the appropriate reset functions. Control Module References

ENGINE OIL PRESSURE SENSOR REPLACEMENT

Fig. 306: Engine Oil Pressure Sensor

Courtesy of GENERAL MOTORS COMPANY

FRONT INTAKE AIR DUCT REPLACEMENT

Fig. 307: Front Intake Air Duct

Courtesy of GENERAL MOTORS COMPANY

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