To the top of the document
Captiva
To Previous Page To Next Page
GMDE Start Page Load static TOC Load dynamic TOC Help?

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE


C7A11C08
Display graphicTranslations of text in graphics


Fuel System Pressure Relief

Procedure

    Caution : The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines.

  1. Remove the fuel cap.
  2. Remove the fuel pump fuse from the engine fuse block.
  3. Start the engine and allow the engine to stall.
  4. Crank the engine for an additional 10 seconds.

C7A11C21
Display graphicTranslations of text in graphics


Fuel Pressure Inspection

Tools Required

DW100-010 Fuel Pressure Gauge

Inspection Procedure

    Caution : The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines.

  1. Relieve the fuel system pressure. Refer to "Fuel System Pressure Relief" in this section.
  2. Disconnect the fuel feed line from the fuel rail.

    3. T3B11F0L
    Display graphicTranslations of text in graphics


  3. Connect the fuel pressure gauge connector to the fuel rail.

    4. T3B11F0M
    Display graphicTranslations of text in graphics


  4. Connect the fuel pressure gauge connector to the fuel feed line.

    5. C7A11FJ2
    Display graphicTranslations of text in graphics


  5. Check the fuel leakage.
  6. Read the fuel pressure gauge DW100-010. Normal fuel pressure is between 402 kPa (58.3 psi) to 418 kPa (60.6 psi).
  7. Relieve the fuel pressure.
  8. Remove the fuel pressure gauge DW100-010.
  9. Connect the fuel feed line to the fuel rail.
  10. Start the engine and check for the fuel leakage.

C7A11G57
Display graphicTranslations of text in graphics


Fuel Tank

Removal Procedure

    Caution : Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

    Caution : The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines.

  1. Disconnect the negative battery cable.
  2. Drain the fuel tank. Ensure that the fuel level in the tank is less than1/4 full. If necessary, drain the fuel tank to at least this level.
  3. Relieve the fuel system pressure. Refer to "Fuel System Pressure Relief" in this section.
  4. Raise and support the vehicle.
  5. Remove the front muffler. Refer to Section 1G2, Engine Exhaust - FAM II 2.4D.
  6. For the AWD vehicle, remove the propeller shaft and rear drive module (RDM). Refer to Section 3B, Rear Drive Axle.

    7. C7A11FO9
    Display graphicTranslations of text in graphics


  7. Disconnect the fuel pump connector at the right rear side of the fuel tank.
  8. Disconnect the fuel tank filler tube, EVAP vent hose and vapor hose from the fuel tank.

    9. C7A11FP0
    Display graphicTranslations of text in graphics


  9. Disconnect the fuel feed line near the right front side of the fuel tank.
  10. Disconnect the fuel vapor pipe from the EVAP emission canister.

    11. C7A11FP3
    Display graphicTranslations of text in graphics


  11. Support the fuel tank.
  12. Remove the parking brake cables support bracket bolts and move it away from the fuel tank.
  13. Remove the fuel tank strap retaining nuts.
  14. Remove the fuel tank straps.
  15. Carefully lower the jack and move the front of the fuel pump downward while tilting the rear of the fuel pump upward.
  16. Remove the fuel tank.

C7A11FP3
Display graphicTranslations of text in graphics


Installation Procedure

  1. Install the fuel tank in the position previously removed.
  2. Install the fuel tank straps.

    3. Tighten
    Tighten the fuel tank strap retaining nuts to 20 N•m (15 lb-ft).

  3. Install the parking brake cables support bracket bolts.

    4. C7A11FP0
    Display graphicTranslations of text in graphics


  4. Connect the fuel vapor pipe to the EVAP emission canister.
  5. Connect the fuel feed line near the right front side of the fuel tank.

    6. C7A11FO9
    Display graphicTranslations of text in graphics


  6. Connect the fuel tank filler tube, EVAP vent hose and vapor hose to the fuel tank.
  7. Connect the fuel pump connector at the right rear side of the fuel tank.
  8. Install the parking brake cables support bracket. Refer to Section 4G, Parking Brake.

    9. C7A11G57
    Display graphicTranslations of text in graphics


  9. Install the front muffler. Refer to Section 1G2, Engine Exhaust - FAM II 2.4D.
  10. For the AWD vehicle, install the propeller shaft and RDM. Refer to Section 3B, Rear Drive Axle.
  11. Fill the fuel tank.
  12. Connect the negative battery cable.
  13. Perform a leak check of the fuel tank and the fuel line connections.

C7A11FM9
Display graphicTranslations of text in graphics


Fuel Pump Assembly

Tools Required

Main Fuel Pump Locking Ring Remover/Installer EN-48279
Sub Fuel Pump Locking Ring Remover/Installer EN-48278

Removal Procedure

    Caution : The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines.

  1. Relieve the fuel system pressure. Refer to "Fuel System Pressure Relief"
  2. Disconnect the negative battery cable.
  3. Fold the rear seat.
  4. Lift up the carpet and the insulation.
  5. Remove the main and sub fuel pump access covers.

    6. C7A11FO0
    Display graphicTranslations of text in graphics


  6. Disconnect the electrical connector at the sub fuel pump assembly.

    7. C7A11FO4
    Display graphicTranslations of text in graphics


  7. Install the sub fuel pump lock ring remover/installer EN-48278 to the sub fuel pump and turn it counterclockwise.
  8. Remove the sub fuel pump lock ring.

    9. Notice : Be careful not to damage the fuel sender for the correct fuel leveling while removing the fuel pump assembly from the fuel tank.

  9. Remove the sub fuel pump assembly and the O-ring from the fuel tank.

    10. Notice : O-ring should not be contaminated by fuel.


    C7A11FO2
    Display graphicTranslations of text in graphics


  10. Disconnect the main fuel pump-to-sub fuel pump connecting hose at the sub fuel pump.

    11. C7A11FO3
    Display graphicTranslations of text in graphics


  11. Disconnect the electrical connector at the main fuel pump assembly.
  12. Disconnect the fuel feed line.

    13. C7A11FO1
    Display graphicTranslations of text in graphics


  13. Install the main fuel pump lock ring remover/installer EN-48279 to the main fuel pump and turn it counterclockwise.
  14. Remove the main fuel pump lock ring.

    15. Notice : Be careful not to damage the fuel sender for the correct fuel leveling while removing the fuel pump assembly from the fuel tank.

  15. Remove the main fuel pump assembly and the O-ring from the fuel tank.

    16. Notice : O-ring should not be contaminated by fuel.


C7A11FO5
Display graphicTranslations of text in graphics


Installation Procedure

  1. Clean all of the mating surface on the both fuel pump and fuel tank.

    2. Notice : For ease of the main fuel pump-to-sub fuel pump connecting hose, install the main fuel pump assembly first.

    Notice : Be sure that the arrow on the main fuel pump assembly should be aligned with the arrow on the fuel tank.

    Notice : Be careful not to damage the fuel sender for the correct fuel leveling while installing the fuel pump assembly to the fuel tank.

    Caution : Do not reuse the main fuel pump O-ring.

  2. Position the new main fuel pump O-ring and the main fuel pump first into the fuel tank in the same location as removed.

    3. C7A11FO2
    Display graphicTranslations of text in graphics


  3. Pull the main fuel pump-to-sub fuel pump connecting hose towards the sub fuel pump assembly.
  4. Connect the main fuel pump-to-sub fuel pump connecting hose at the sub fuel pump.

    5. C7A11FO6
    Display graphicTranslations of text in graphics


    Notice : Be sure that the arrow on the sub fuel pump assembly should be aligned with the arrow on the fuel tank.

    Notice : Be careful not to damage the fuel sender for the correct fuel leveling while installing the fuel pump assembly to the fuel tank.

    Caution : Do not reuse the sub fuel pump O-ring.

  5. Position the new sub fuel pump O-ring and the sub fuel pump into the fuel tank in the same location as removed.

    6. C7A11FO0
    Display graphicTranslations of text in graphics


  6. Install the sub fuel pump lock ring by turning the sub fuel pump lock ring remover/installer EN-48278 clockwise.
  7. Connect the electrical connector at the sub fuel pump.

    8. C7A11FO3
    Display graphicTranslations of text in graphics


  8. Install the main fuel pump lock ring by turning the main fuel pump lock ring remover/installer EN-48279 clockwise.
  9. Connect the electrical connector at the main fuel pump.
  10. Connect the fuel feed line.

    11. C7A11FM9
    Display graphicTranslations of text in graphics


  11. Install the main and sub fuel pump access covers.
  12. Connect the negative battery cable.
  13. Perform an operational check of the fuel pump.
  14. Fold the rear seat back to the original position.

C7A11FO7
Display graphicTranslations of text in graphics


Fuel Sender

Replacement Procedure

    Notice : The illustrations in this section show the fuel sender on the main fuel pump ONLY. The fuel sender on the sub fuel pump is similar.

    Notice : Be careful not to damage the fuel sender for the correct fuel leveling while removing or installing the fuel pump assembly from the fuel tank.

  1. Remove the fuel pump assembly. Refer to "Fuel Pump Assembly" in this section.
  2. Disconnect the fuel sender connector.

    3. C7A11FO8
    Display graphicTranslations of text in graphics


  3. Press the locking tap by using a suitable tool such as a screwdriver.
  4. Remove the fuel sender assembly by sliding it out from the fuel pump.

    5. Notice : Improper installation of the fuel sender on the fuel pump may cause the incorrect fuel leveling.

  5. Install the fuel sender in the reverse order of removal.
  6. Install the fuel pump assembly into the fuel tank. Refer to "Fuel Pump Assembly" in this section.

Fuel Filter

Notice : The fuel filter is assembled within the fuel pump. It cannot be replaced separately. The fuel filter should be replaced as a fuel pump assembly, if needed. Refer to "Fuel Pump" in this section.


C7A11C01
Display graphicTranslations of text in graphics


Fuel Rail and Injectors

Removal Procedure

    Caution : the fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines.

  1. Relieve the fuel system pressure. Refer to " Fuel System Pressure Relief " in this section.
  2. Disconnect the negative battery cable.
  3. Disconnect the intake air temperature (IAT) sensor connector.
  4. Loosen the clamp and disconnect the air cleaner outlet hose from the resonator.

    5. C7A11C09
    Display graphicTranslations of text in graphics


  5. Loosen the clamp and remove the resonator from the electronic throttle body.

    6. C7A11C21
    Display graphicTranslations of text in graphics


  6. Remove the engine cover.
  7. Disconnect the breather hose and PCV hose from the cylinder head cover.
  8. Disconnect the fuel feed line at the fuel rail.

    9. C7A11C53
    Display graphicTranslations of text in graphics


  9. Connect the fuel injector connectors.
  10. Remove the fuel rail retaining bolts.

    11. Notice : Before removal, the fuel rail assembly may be cleaned with a spray-type cleaner, following the package instructions. Do not immerse the fuel rails in liquid cleaning solvent. Use care in removing the fuel rail assembly to prevent damage to the electrical connectors and the injector spray tips. Prevent dirt and other contaminants from entering open lines and passages. Fittings should be capped and holes should be plugged during service.

    Important : If an injector becomes separated from the rail and remain in the cylinder head, replace the injector O-ring seals and the retaining clip.

  11. Remove the fuel rail with the injectors attached.

    12. V3B11F74
    Display graphicTranslations of text in graphics


  12. Remove the fuel injector retainer clips.
  13. Remove the fuel injectors by pulling them down and out.
  14. Discard the fuel injector O-rings.

V3B11F75
Display graphicTranslations of text in graphics


Installation Procedure

    Important : Different injectors are calibrated for different flow rates. When ordering new fuel injectors, be certain to order the identical part number that is inscribed on the old injector.

  1. Lubricate the new fuel injector O-rings with engine oil. Install the new O-rings on the fuel injectors.
  2. Install the fuel injectors into the fuel rail sockets with the fuel injector terminals facing outward.
  3. Install the fuel injector retaining clips onto the fuel injector and the fuel rail ledge.
  4. Make sure that the clips are parallel to the fuel injector harness connector.

    5. C7A11C53
    Display graphicTranslations of text in graphics


  5. Install the fuel rail assembly into the cylinder head.
  6. Install the fuel rail retaining bolts.

    7. Tighten
    Tighten the fuel rail retaining bolts to 25 N•m (18 lb-ft).


    C7A11C21
    Display graphicTranslations of text in graphics


  7. Connect the fuel injector connectors. Rotate each fuel injector as required.
  8. Connect the fuel feed line to the fuel rail.

    9. C7A11C09
    Display graphicTranslations of text in graphics


  9. Install the resonator to the electronic throttle body.

    10. C7A11C01
    Display graphicTranslations of text in graphics


  10. Connect the air cleaner outlet hose to the resonator.
  11. Connect the breather hose and PCV hose to the cylinder head cover.
  12. Connect the IAT sensor connector.
  13. Install the engine cover.
  14. Connect the negative battery cable.
  15. Perform a leak check of the fuel rail and fuel injectors.

J4B31F82
Display graphicTranslations of text in graphics


Engine Coolant Temperature (ECT) Sensor

Removal Procedure

  1. Relieve the coolant system pressure.
  2. Disconnect the negative battery cable.
  3. Disconnect the engine coolant temperature (ECT) sensor connector.

    4. Notice : Take care when handling the engine coolant temperature sensor. Damage to the sensor will affect the proper operation of the fuel injection system.

  4. Remove the ECT sensor from the exhaust gas recirculation (EGR) valve adapter.

V3B11F79
Display graphicTranslations of text in graphics


Installation Procedure

  1. Coat the threads of the ECT sensor with sealer.
  2. Install the ECT sensor into the EGR valve adapter. adapter.

    3. Tighten
    Tighten the engine coolant temperature sensor to 20 N•m (15 lb-ft).

  3. Connect the ECT sensor connector.
  4. Fill the coolant system.
  5. Connect the negative battery cable.

C7A11C01
Display graphicTranslations of text in graphics


Electronic Throttle Body

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the intake air temperature (IAT) sensor connector.
  3. Loosen the clamp and disconnect the air cleaner outlet hose from the resonator.

    4. C7A11C09
    Display graphicTranslations of text in graphics


  4. Loosen the clamp and remove the resonator from the electronic throttle body.
  5. Remove the engine cover.
  6. Disconnect the breather hose and PCV hose from the cylinder head cover.

    7. C7A11FJ7
    Display graphicTranslations of text in graphics


  7. Disconnect the coolant hoses from the electronic throttle body.
  8. Disconnect the electronic throttle control (ETC) connector.

    9. C7A11FJ8
    Display graphicTranslations of text in graphics


    Notice : The electronic throttle body control unit must not be removed from the electronic throttle body.

  9. Remove the electronic throttle body retaining bolts.
  10. Remove the electronic throttle body and the electronic throttle body gasket.

C7A11FJ9
Display graphicTranslations of text in graphics


Installation Procedure

    Notice : Use care in cleaning old gasket material from the machined aluminum surfaces. Sharp tools may damage sealing surfaces.

  1. Clean the gasket mating surface on the intake manifold.

    2. Notice : The electronic throttle body may be cleaned in a cold immersion-type cleaner following disassembly.

  2. Clean the electronic throttle body.
  3. Install the electronic throttle body assembly with a new gasket to the intake manifold.

    4. C7A11FJ8
    Display graphicTranslations of text in graphics


  4. Install the electronic throttle body retaining bolts.

    5. Tighten
    Tighten the electronic throttle body retaining bolts to 10 N•m (89 lb-in).


    C7A11FJ7
    Display graphicTranslations of text in graphics


  5. Connect the ETC connector.
  6. Connect the coolant hoses to the electronic throttle body.

    7. C7A11C01
    Display graphicTranslations of text in graphics


  7. Install the resonator to the electronic throttle body.
  8. Connect the air cleaner outlet hose to the resonator.
  9. Connect the breather hose and PCV hose to the cylinder head cover.
  10. Connect the IAT sensor connector.
  11. Connect the negative battery cable.
  12. Fill the cooling system.
  13. Reset all learned values in ECM.

C7A11C54
Display graphicTranslations of text in graphics


Front Heated Oxygen Sensor

Tools Required

DW170-010 Oxygen Sensor Remover/Installer

Removal Procedure

  1. Disconnect the negative battery cable.

    2. Notice : The oxygen sensor used a permanently attached pigtail and connector. This pigtail should not be removed from the oxygen sensor. Damage or removal of the pigtail or the connector affect the proper operation of the oxygen sensor. Take care when handing the oxygen sensor. Do not drop the oxygen sensor.

  2. Disconnect the front heated oxygen sensor connector.

    3. C7A11FM7
    Display graphicTranslations of text in graphics


    Caution : Allow the engine to cool before removing the oxygen sensor. Removal of the oxygen sensor when the engine is hot may damage the threads in the exhaust manifold.

  3. Using the oxygen sensor remover/installer DW170-010, carefully remove the front heated oxygen sensor.

C7A11FM7
Display graphicTranslations of text in graphics


Installation Procedure

    Important : A special anti-seize compound is used on the oxygen sensor threads. This compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or serviced sensors will already have the compound applied to the threads. If a sensor is removed from any engine and is to be reinstalled, the threads must have an anti-seize compound applied before reinstallation.

  1. Coat the threads of the front heated oxygen sensor with anti-seize compound, if needed.
  2. Using the oxygen sensor remover/installer DW170-010, install the front heated oxygen sensor into the exhaust manifold.

    3. Tighten
    Tighten the front heated oxygen sensor to 50 N•m (37 lb-ft).


    C7A11C54
    Display graphicTranslations of text in graphics


  3. Connect the front heated oxygen sensor connector.
  4. Connect the negative battery cable.

C7A11FL4
Display graphicTranslations of text in graphics


Rear Heated Oxygen Sensor

Tools Required

DW170-010 Oxygen Sensor Remover/Installer

Removal Procedure

  1. Disconnect the negative battery cable.

    2. Notice : The oxygen sensor used a permanently attached pigtail and connector. This pigtail should not be removed from the oxygen sensor. Damage or removal of the pigtail or the connector affect the proper operation of the oxygen sensor. Take care when handing the oxygen sensor. Do not drop the oxygen sensor.

  2. Disconnect the rear heated oxygen sensor connector.

    3. C7A11FM8
    Display graphicTranslations of text in graphics


    Caution : Allow the engine to cool before removing the oxygen sensor. Removal of the oxygen sensor when the engine is hot may damage the threads in the exhaust manifold.

  3. Using the oxygen sensor remover/installer DW170-010, carefully remove the rear heated oxygen sensor.

C7A11FM8
Display graphicTranslations of text in graphics


Installation Procedure

    Important : A special anti-seize compound is used on the oxygen sensor threads. This compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or serviced sensors will already have the compound applied to the threads. If a sensor is removed from any engine and is to be reinstalled, the threads must have an anti-seize compound applied before reinstallation.

  1. Coat the threads of the rear oxygen sensor with anti-seize compound, if needed.
  2. Using the oxygen sensor remover/installer DW170-010, install the rear heated oxygen sensor into the exhaust front pipe.

    3. Tighten
    Tighten the rear heated oxygen sensor to 50 N•m (37 lb-ft).


    C7A11FL4
    Display graphicTranslations of text in graphics


  3. Connect the rear heated oxygen sensor connector.
  4. Connect the negative battery cable.

C7A11FM3
Display graphicTranslations of text in graphics


Accelerator Pedal Module (APM)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the accelerator pedal module (APM) connector locking tab from the APM connector.
  3. Disconnect the APM connector.

    4. C7A11FM4
    Display graphicTranslations of text in graphics


  4. Remove the bolts, three places, attaching the APM from the accelerator and brake pedal module bracket.

C7A11FM4
Display graphicTranslations of text in graphics


Installation Procedure

  1. Install the APM retaining bolts to the accelerator and brake pedal module bracket.

    2. Tighten
    Tighten the accelerator pedal module retaining bolts to 9 N•m (80 lb-in).


    C7A11FM3
    Display graphicTranslations of text in graphics


  2. Connect the APM connector and the install the locking tab firmly.

C7A11C01
Display graphicTranslations of text in graphics


Intake Air Temperature (IAT) Sensor

Removal Procedure

    Caution : Do not remove the IAT sensor from the air cleaner outlet hose. Replace only the air cleaner outlet hose assembly with the IAT sensor attached, if necessary.

  1. Disconnect the negative battery cable.
  2. Disconnect the intake air temperature (IAT) sensor connector.
  3. Loosen the both clamp at the air cleaner outlet hose and replace the air cleaner outlet hose assembly with the IAT sensor attached.

C7A11C01
Display graphicTranslations of text in graphics


Installation Procedure

  1. Install the air cleaner outlet hose with the IAT sensor attached.
  2. Connect the IAT sensor connector.
  3. Connect the negative battery cable.

C7A11C01
Display graphicTranslations of text in graphics


Manifold Absolute Pressure (MAP) Sensor

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the intake air temperature (IAT) sensor connector.
  3. Loosen the clamp and disconnect the air cleaner outlet hose from the resonator.

    4. C7A11C09
    Display graphicTranslations of text in graphics


  4. Loosen the clamp and remove the resonator from the electronic throttle body.

    5. C7A11FM1
    Display graphicTranslations of text in graphics


  5. Remove the fuel rail. Refer to "Fuel Rail and Injectors" in this section.
  6. Disconnect the manifold absolute pressure (MAP) sensor connector.

    7. C7A11FM2
    Display graphicTranslations of text in graphics


  7. Remove the MAP sensor retaining bolt.
  8. Remove the MAP sensor from the intake manifold.

C7A11FM2
Display graphicTranslations of text in graphics


Installation Procedure

  1. Install the MAP sensor to the intake manifold.
  2. Install the MAP sensor retaining bolt.

    3. Tighten
    Tighten the manifold absolute pressure sensor retaining bolt to 4 N•m (35 lb-in).


    C7A11FM1
    Display graphicTranslations of text in graphics


  3. Install the fuel rail. Refer to "Fuel Rail and Injectors" in this section.
  4. Connect the MAP sensor connector.
  5. Install the resonator to the electronic throttle body.
  6. Connect the air cleaner outlet hose to the resonator.
  7. Connect the IAT sensor connector.
  8. Connect the negative battery cable.

C7A11FK0
Display graphicTranslations of text in graphics


Exhaust Gas Recirculation (EGR) Valve

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the EGR valve connector.
  3. Remove the EGR valve retaining bolts.
  4. Remove the EGR valve and the gasket from the EGR valve adapter.

C7A11FK1
Display graphicTranslations of text in graphics


Installation Procedure

  1. Clean the EGR valve adapter mating surface.
  2. Install a new EGR valve gasket.

    3. C7A11FK0
    Display graphicTranslations of text in graphics


  3. Install the EGR valve with the bolts.

    4. Tighten
    Tighten the exhaust gas recirculation valve retaining bolts to 30 N•m (22 lb-ft).

  4. Connect the EGR valve connector.
  5. Connect the negative battery cable.

C7A11FK2
Display graphicTranslations of text in graphics


Exhaust Gas Recirculation (EGR) Valve Adapter and Internal PCV Pipe

Removal Procedure

  1. Disconnect the negative battery cable.

    2. Caution : To prevent personal injury, do not remove the surge tank cap while the engine and the radiator are hot because the heat causes the system to remain under pressure. Scalding fluid and steam may be blown out under pressure.

  2. Drain the coolant fluid. Refer to Section 1D2, Engine Cooling - FAM II 2.4D.
  3. Remove the engine cover.
  4. Remove the ignition wires from the direct ignition system (DIS).
  5. Disconnect the exhaust gas recirculation (EGR) valve connector, engine coolant temperature (ECT) sensor connector and the DIS connector.

    6. J6B31F99
    Display graphicTranslations of text in graphics


  6. Disconnect the heater return hose at the EGR valve adapter.
  7. Remove the EGR valve adapter retaining bolts.
  8. Remove the EGR valve adapter and the internal PCV pipe with the gasket.

J6B31F98
Display graphicTranslations of text in graphics


Installation Procedure

  1. Install the EGR valve adapter and internal PCV pipe with the gasket.
  2. Install the EGR valve adapter retaining bolts.

    3. Tighten
    Tighten the EGR valve adapter retaining bolts (1) to 20 N•m (15 lb-ft).
    Tighten the EGR valve adapter retaining bolts (2) to 30 N•m (22 lb-ft).

  3. Connect the heater return hose to the EGR valve adapter.

    4. C7A11FK2
    Display graphicTranslations of text in graphics


  4. Connect the EGR valve connector, ECT sensor connector and the DIS connector
  5. Connect the ignition wire to the DIS system.
  6. Install the engine cover.
  7. Connect the negative battery cable.
  8. Fill the coolant system.

C7A11FK5
Display graphicTranslations of text in graphics


Knock Sensor

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Raise and suitably support the vehicle.
  3. Disconnect the knock sensor connector.

    4. C7A11FK6
    Display graphicTranslations of text in graphics


  4. Remove the knock sensor retaining bolt.
  5. Remove the knock sensor.

C7A11FK6
Display graphicTranslations of text in graphics


Installation Procedure

  1. Install the knock sensor with the bolt.

    2. Tighten
    Tighten the knock sensor retaining bolt to 20 N•m (15 lb-ft).


    C7A11FK5
    Display graphicTranslations of text in graphics


  2. Connect the knock sensor connector.
  3. Lower the vehicle.
  4. Connect the negative battery cable.

C7A11FK7
Display graphicTranslations of text in graphics


Evaporative (EVAP) Emission Canister Assembly

Removal Procedure

    Caution : Canister and vacuum hoses contain the fuel vapors. Do not smoke in the area or permit an open flame.

  1. Disconnect the canister fuel vapor hoses from the canister.

    2. C7A11FM5
    Display graphicTranslations of text in graphics


  2. Loosen the clamp and disconnect the evaporative (EVAP) emission canister vent hose from the EVAP emission canister filter.

    3. C7A11FK8
    Display graphicTranslations of text in graphics


  3. Remove the EVAP emission canister bracket retaining nuts and the EVAP emission canister assembly.
  4. Separate the canister from the EVAP emission canister bracket.
  5. Remove the canister.

C7A11FK8
Display graphicTranslations of text in graphics


Installation Procedure

  1. Install the EVAP emission canister onto the EVAP emission canister bracket.
  2. Install the EVAP emission canister assembly.

    3. Tighten
    Tighten the evaporative emission canister bracket retaining nuts to 10 N•m (89 lb-in).


    C7A11FM5
    Display graphicTranslations of text in graphics


  3. Connect the EVAP emission canister vent hose to the EVAP emission canister filter.

    4. C7A11FK7
    Display graphicTranslations of text in graphics


  4. Connect the canister fuel vapor hoses to the canister.

V3B11F96
Display graphicTranslations of text in graphics


Evaporative (EVAP) Emission Canister Purge Solenoid Valve

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the evaporative (EVAP) emission canister purge solenoid valve connector.
  3. Disconnect the vacuum hoses from the EVAP canister purge solenoid.
  4. Remove the EVAP canister purge solenoid valve bracket bolt from the intake manifold.
  5. Unclip the EVAP canister purge solenoid valve from the mounting bracket.

V3B11F96
Display graphicTranslations of text in graphics


Installation Procedure

  1. Attach the EVAP canister purge solenoid valve to the mounting bracket.
  2. Install the EVAP canister purge solenoid valve and the mounting bracket to the intake manifold with the bracket bolt.

    3. Tighten
    Tighten the evaporative emission canister purge solenoid valve bracket bolt to 5 N•m (44 lb-in).

  3. Connect the vacuum hoses to the EVAP canister purge solenoid valve.
  4. Connect the EVAP canister purge solenoid valve connector.
  5. Connect the negative battery cable.

C7A11FM6
Display graphicTranslations of text in graphics


Evaporative (EVAP) Emission Canister Filter

Removal Procedure

  1. Remove the EVAP emission canister assembly. Refer to "Evaporative Emission Canister Assembly" in this section.
  2. Loosen the clamp and disconnect the EVAP emission canister vent hose from the EVAP emission canister filter.
  3. Remove the EVAP canister emission canister filter by unclipping the clips from the EVAP emission canister bracket.

C7A11FM6
Display graphicTranslations of text in graphics


Installation Procedure

  1. Install the EVAP emission canister filter to the EVAP emission canister bracket.
  2. Connect the EVAP emission canister vent hose to the EVAP emission canister filter.
  3. Install the EVAP emission canister assembly. Refer to "Evaporative Emission Canister Assembly" in this section.

C7A11FL1
Display graphicTranslations of text in graphics


Evaporative (EVAP) Emission Pipe Assembly

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the EVAP emission canister purge front hose from the EVAP emission canister purge solenoid valve.
  3. Disconnect the EVAP emission canister purge front hose from the EVAP emission pipe.

    4. C7A11FL2
    Display graphicTranslations of text in graphics


  4. Disconnect the EVAP emission pipe rear hose from the EVAP emission canister.

    5. C7A11FL3
    Display graphicTranslations of text in graphics


  5. Remove the EVAP emission canister vapor pipe protector bracket.
  6. Remove the EVAP emission canister vapor pipe retaining clips.
  7. Remove the EVAP emission canister vapor pipe.

C7A11FL3
Display graphicTranslations of text in graphics


Installation Procedure

  1. Install the EVAP emission canister vapor pipe with the retaining clips.
  2. Install the EVAP emission canister vapor pipe retaining clips.
  3. Install the EVAP emission canister vapor pipe protector bracket.

    4. C7A11FL2
    Display graphicTranslations of text in graphics


  4. Connect the EVAP emission pipe rear hose to the EVAP emission canister.

    5. C7A11FL1
    Display graphicTranslations of text in graphics


  5. Connect the EVAP emission canister purge front hose to the EVAP emission canister pipe.
  6. Connect the EVAP emission canister purge front hose to the EVAP emission canister purge solenoid valve.

V3B11F99
Display graphicTranslations of text in graphics


Crankshaft Position (CKP) Sensor

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the power steering pump. Refer to Section 6B, Power Steering Pump.
  3. Remove the A/C compressor. Refer to Section 7B, Manual Control Heating, Ventilation and Air Conditioning System.
  4. Remove the rear A/C compressor mounting bracket bolts and the rear A/C compressor mounting bracket.

    5. V3B11F97
    Display graphicTranslations of text in graphics


  5. Remove the accessory mounting bracket by removing the bolts.

    6. V3B11F98
    Display graphicTranslations of text in graphics


  6. Disconnect the crankshaft position (CKP) sensor connector.
  7. Remove the CKP sensor retaining bolt.
  8. Gently rotate and remove the CKP sensor from the engine block.

V3B11F98
Display graphicTranslations of text in graphics


Installation Procedure

  1. Install the CKP sensor into the engine block.
  2. Install the CKP sensor retaining bolt.

    3. Tighten
    Tighten the CKP sensor retaining bolt to 8 N•m (71 lb-in).

  3. Connect the CKP sensor connector.

    4. V3B11F97
    Display graphicTranslations of text in graphics


  4. Install the accessory mounting bracket with the bolts.

    5. Tighten
    Tighten the accessory mounting bracket bolts to 37 N•m (27 lb-ft).


    V3B11F99
    Display graphicTranslations of text in graphics


  5. Install the rear A/C mounting bracket.

    6. Tighten
    Tighten the rear A/C mounting bracket bolts to 35 N•m (26 lb-ft).

  6. Install the A/C compressor. Refer to Section 7B, Manual Control Heating, Ventilation and Air Conditioning System.
  7. Install the power steering pump. Refer to Section 6B, Power Steering Pump.
  8. Connect the negative battery cable.

C7A11FL7
Display graphicTranslations of text in graphics


Camshaft Position (CMP) Sensor

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the engine cover.
  3. Disconnect the camshaft position (CMP) sensor connector.

    4. C7A11C58
    Display graphicTranslations of text in graphics


  4. Remove the timing belt front cover. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D.
  5. Remove the CMP sensor bolts.
  6. Remove the CMP sensor from the top.

C7A11C58
Display graphicTranslations of text in graphics


Installation Procedure

  1. Install the CMP sensor with the bolts.

    2. Tighten
    Tighten the camshaft position sensor bolts to 8 N•m (71 lb-in).


    C7A11FL7
    Display graphicTranslations of text in graphics


  2. Install the timing belt front cover. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D.
  3. Connect the CMP sensor connector.
  4. Install the engine cover.
  5. Connect the negative battery cable.

C7A11FL9
Display graphicTranslations of text in graphics


Direct Ignition System (DIS)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the direct ignition system (DIS) connector.
  3. Note the ignition wires' location and remove the ignition wires.

    4. C7A11FM0
    Display graphicTranslations of text in graphics


  4. Remove the DIS retaining bolts.
  5. Remove the DIS.

C7A11FM0
Display graphicTranslations of text in graphics


Installation Procedure

  1. Install the DIS into the mounting location and install the retaining bolts.

    2. Tighten
    Tighten the direct ignition system retaining bolts to 10 N•m (89 lb-in).


    C7A11FL9
    Display graphicTranslations of text in graphics


  2. Connect the DIS connector.
  3. Install the ignition wires.
  4. Connect the negative battery cable.

C7A11E55
Display graphicTranslations of text in graphics


Engine Control Module (ECM)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the engine control module (ECM) connectors from the ECM.

    3. C7A11E56
    Display graphicTranslations of text in graphics


  3. Remove the ECM bracket retaining nuts.
  4. Remove the ECM with the bracket attached from the battery tray.

    5. C7A11E57
    Display graphicTranslations of text in graphics


  5. Unclip the ECM to the bracket and separate the ECM from the bracket.

C7A11E56
Display graphicTranslations of text in graphics


Installation Procedure

  1. Install the ECM into the bracket.
  2. Install the ECM with the bracket attached to the battery tray.

    3. Tighten
    Tighten the ECM bracket retaining nuts to 15 N•m (11 lb-ft).


    C7A11E55
    Display graphicTranslations of text in graphics


  3. Connect the ECM connectors to the ECM.
  4. Connect the negative battery cable.

    5. Caution : If the ECM has been replaced, perform the ECM reprogramming process.



To Previous Page To Next Page
© Copyright Chevrolet Europe. All rights reserved