Aveo 2009 PDF

Document ID: 1591851 Page 1 of 1
2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Controls and Fuel - 1.6L (LXT)
| Specifications | Document ID: 1591851
Temperature Versus Resistance

°C °F ECT Ohms IAT Ohms
Temperature vs Resistance Values (Approximate)
100 212 177 187
90 194 241 246
80 176 332 327
70 158 467 441
60 140 667 603
50 122 973 837
45 113 1188 991
40 104 1459 1180
35 95 1802 1412
30 86 2238 1700
25 77 2796 2055
20 68 3520 2500
15 59 4450 3055
10 50 5670 3760
5 41 7280 4651
0 32 9420 5800
-5 23 12300 7273
-10 14 16180 9200
-15 5 21450 9200
-20 -4 28680 15080
-30 -22 52700 25600
-40 -40 100700 45300
© 2010 General Motors Corporation. All rights reserved.
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Altitude Versus Barometric Pressure

Altitude Measured in Altitude Measured in Barometric Pressure Measured in
Meters (m) Feet (ft) Kilopascals (kPa)
Determine your altitude by contacting a local weather station or by using another reference
source.
4 267 14,000 56-64
3 962 13,000 58-66
3 658 12,000 61-69
3 353 11,000 64-72
3 048 10,000 66-74
2 743 9,000 69-77
2 438 8,000 71-79
2 134 7,000 74-82
1 829 6,000 77-85
1 524 5,000 80-88
1 219 4,000 83-91
914 3,000 87-95
610 2,000 90-98
305 1,000 94-102
0 0 Sea Level 96-104
-305 -1,000 101-105

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Ignition System Specifications

Specification
Application Metric English
Firing Order 1-3-4-2
Spark Plug Wire Resistance 2,000-12,000 ohms
Spark Plug Gap 1.0-1.1 mm 0.039-0.043 in
Spark Plug Torque 25 N·m 18 lb ft
Spark Plug Type Woojin - BKR6E-11

Fastener Tightening Specifications

Specification
Application Metric English
Accessory Mounting Bracket Bolts 37 N·m 27 lb ft
Camshaft Position Sensor Bolts 12 N·m 106 lb in
Crankshaft Position Sensor Retaining Bolt 6.5 N·m 58 lb in
Electronic Ignition System Ignition Coil Retaining Bolts 10 N·m 89 lb in
Engine Control Module Bolts 4 N·m 35 lb in
Engine Coolant Temperature Sensor Bolt 20 N·m 15 lb ft
Evaporative Emission Canister Flange Bolt 20 N·m 15 lb ft
Evaporative Emission Canister Protective Cover 8 N·m 71 lb in
Evaporative Emission Canister Purge Solenoid Bracket Bolt 5 N·m 44 lb in
Evaporative Emission Vent Solenoid Bolt 8.5 N·m 75 lb in
Exhaust Gas Recirculation Valve Retaining Bolts 30 N·m 22 lb ft
Fuel Filter Mounting Bracket Assembly Bolt 4 N·m 35 lb in
Fuel Pressure Regulator Retaining Screw 12 N·m 106 lb in
Fuel Rail Retaining Bolts 25 N·m 18 lb ft
Fuel Tank Retaining Bolts 20 N·m 15 lb ft
Idle Air Control Valve Retaining Bolts 3 N·m 27 lb in
Knock Sensor Bolt 20 N·m 15 lb ft
Manifold Absolute Pressure Sensor Mounting Bracket Bolt 4 N·m 35 lb in
Manifold Absolute Pressure Sensor Retaining Bolts and Nuts 8 N·m 71 lb in
Oxygen Sensor Bolt 42 N·m 31 lb ft
Rear A/C Compressor Mounting Bracket Bolts 35 N·m 26 lb ft
Spark Plug Cover Bolts 3 N·m 27 lb in
Throttle Body Retaining Nuts 15 N·m 11 lb ft
Throttle Position Sensor Retaining Bolts 2 N·m 18 lb in
Variable Geometry Induction System Solenoid 10 N·m 89 lb in

| Schematic and Routing Diagrams | Document ID: 1497903
Emission Hose Routing Diagram
(1) To HVAC
(2) Vacuum Brake Booster
(3) Evaporative Emissions (EVAP) Canister
(4) EVAP Vent Solenoid
(5) Fuel Tank
Intake Manifold Tuning Valve (IMTV) Vacuum Actuator/Variable Geometry Induction System
(6)
(VGIS) Vacuum Actuator)
(7) IMTV Solenoid/VGIS Solenoid
(8) IMTV Vacuum Reservoir/VGIS Vacuum Reservoir
(9) EVAP Purge Solenoid
(10) Manifold Absolute Pressure (MAP) Sensor

Evaporative Emissions Hose Routing Diagram
(1) Intake Manifold

(2) Evaporative Emissions (EVAP) Canister Purge Solenoid Valve
(3) Service Port
(4) Evaporative Emissions (EVAP) Canister
(5) Evaporative Emissions (EVAP) Canister Vent Solenoid Valve
(6) Air Filter
(7) Fresh Air Intake
(8) Fuel Filler Cap
(9) Fuel Filler Tube
(10) Check Valve
(11) Fuel Tank
(12) Fuel Fill Vent Valve
(13) Fuel Level at Shut-Off
(14) Fuel Pressure Relief Valve
(15) Fuel Tank Pressure Sensor
(16) Rollover Valve

Fuel Hose/Pipes Routing Diagram
(1) Fuel Tank

(2) Fuel Line to Fuel Rail
(3) EVAP Canister Purge Vacuum Line to Intake Manifold
(4) EVAP Canister Purge Solenoid Valve
(5) EVAP Service Port
(6) EVAP Canister Vent Solenoid Valve
(7) EVAP Canister
(8) Fuel Fill Tube
(9) Fuel Filler Cap
(10) Fuel Tank Pressure Sensor (FTP)
(11) Fuel Sender Assembly

| Repair Instructions | Document ID: 2098050
Engine Control Module Replacement

Removal Procedure
Warning: Refer to Battery Disconnect Warning in the Preface section.
1. Disconnect the negative battery cable.

2. Disconnect the engine control module (ECM) connectors.
3. Remove the ECM retaining nuts.


4. Remove the ECM from the ECM mount.
Installation Procedure
1. Position the ECM in place.
Caution: Refer to Fastener Caution in the Preface section.
2. Install the ECM to the ECM mount and install the retaining bolts.
Tighten
Tighten the ECM retaining bolts to 4 N·m (35 lb in).

3. Connect the ECM connectors.

4. Connect the negative battery cable.
5. Perform the following procedures:
• Program the ECM
• Crankshaft Position System Variation Learn
• Idle Learn
6. Refer to Control Module References for programming and setup information.

Crankshaft Position System Variation Learn

Important: If the crankshaft position variation learn procedure has not learned, a false misfire
could be detected and DTC P0300 may set. If sent here from DTC P0300, proceed with the
crankshaft position variation learn procedure.
1. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set,
except DTC P0300, or P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the
applicable DTC.
2. Select the crankshaft position variation learn procedure with a scan tool.
3. The scan tool instructs you to perform the following:
3.1. Accelerate to wide open throttle (WOT).
3.2. Release throttle when fuel cut-off occurs.
3.3. Observe fuel cut-off for applicable engine.
3.4. Engine should not accelerate beyond calibrated RPM value.
3.5. Release throttle immediately if value is exceeded.
3.6. Block drive wheels.
3.7. Set parking brake.
3.8. DO NOT apply brake pedal.
3.9. Cycle ignition from OFF to ON.
3.10. Apply and hold brake pedal.
3.11. Start and idle engine.
3.12. Turn A/C OFF.
Vehicle must remain in Park or Neutral.
The scan tool monitors certain component signals to determine if all the conditions are met to
continue with the procedure. The scan tool only displays the condition that inhibits the
procedure. The scan tool monitors the following components:
• Crankshaft position (CKP) sensors activity--If there is a CKP sensor condition, refer to
the applicable DTC.
• Camshaft position (CMP) signal activity--If there is a CMP signal condition, refer to the
applicable DTC.
• 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.
4. Enable the CKP system variation learn procedure with the scan tool and perform the
following:
Important: While the CKP variation learn procedure is in progress, hold the throttle at
WOT for 5 fuel-cutoffs. The learn procedure must determine there has been 5 fuel-cutoffs
to properly perform the test.
• Accelerate to WOT.

• Hold throttle while fuel cut-off occurs.

5. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that
DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool
indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to
Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC.
6. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully.
The CKP system variation learn procedure is also required when the following service procedures
have been performed, regardless of whether or not DTC P0315 is set:
• An engine replacement
• An ECM replacement
• A harmonic balancer replacement
• A crankshaft replacement
• A CKP sensor replacement
• Any engine repairs which disturb the crankshaft to CKP sensor relationship.

Idle Learn
The Idle Learn Procedure listed below must be performed whenever the following occurs:
• The throttle body assembly is replaced

• The throttle body is cleaned
• The engine control module (ECM) is replaced
• The idle air control valve (IAC) is replaced
• Power disconnection (battery cable, ECM fuse, etc.) (Delphi ECM only)
1.Turn the ignition ON.

2.Turn the ignition OFF for 15 seconds.
3.Turn the ignition ON for 5 seconds.
4.Turn the ignition OFF for 15 seconds.
5.Start the engine in park/neutral.
6.Allow the engine to run until the engine coolant temperature is greater than 85°C (185°F).
7.Turn the A/C ON for 10 seconds, if equipped.
8.If the vehicle is equipped with an automatic transaxle, apply the parking brake. While
pressing the brake pedal, place the transaxle in drive (D) for 10 seconds.
9. Turn the A/C OFF for 10 seconds, if equipped.
10. If the vehicle is equipped with an automatic transaxle, while pressing the brake pedal, place
the transaxle in park/neutral.
11. Turn the ignition OFF. The idle learn procedure is complete.

Engine Coolant Temperature Sensor Replacement

Removal Procedure
1. Relieve the coolant system pressure.

3. Drain the coolant below the engine coolant temperature (ECT) sensor level.
4. Disconnect the ECT sensor connector.
Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will
affect the operation of the fuel control system.
5. Remove the ECT sensor.

1. Install the ECT sensor.
Tighten
Tighten the ECT sensor to 20 N·m (15 lb ft).
2. Connect the ECT sensor connector.

3. Fill the cooling system. Refer to Cooling System Draining and Filling.

Manifold Absolute Pressure Sensor Replacement

Removal Procedure

2. Remove the manifold absolute pressure (MAP) sensor electrical connector.
3. Disconnect the vacuum hose.
4. Remove the MAP sensor bolt.
5. Remove the MAP sensor.

1. Install the MAP sensor with the bolt.
Tighten
Tighten the MAP sensor bolt to 10 N·m (89 lb in).
2. Connect the vacuum hose.

3. Connect the MAP sensor electrical connector.

Heated Oxygen Sensor Replacement - Sensor 1

Special Tools
EN-46577 Oxygen Sensor Remover/Installer
Removal Procedure
Caution: Refer to Heated Oxygen and Oxygen Sensor Caution in the Preface section.
2. Disconnect the front heated oxygen sensor (HO2S1) connector.
Caution: Remove oxygen sensors with the engine temperature above 48°C (120°F).
Otherwise the oxygen sensors may be difficult to remove.
3. Carefully remove the HO2S1 from the exhaust manifold using EN-46577 .

Note: 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 service sensors will already
have the compound applied to the threads. If a sensor is removed from any engine and if for
any reason it is to be reinstalled, the threads must have anti-seize compound applied before
reinstallation.
1. Coat the threads of the HO2S1 will an anti-seize compound, if needed.
2. Install the HO2S1 to the exhaust manifold using EN-46577 .
Tighten
Tighten the oxygen sensor to 42 N·m (31 lb ft).
3. Connect the HO2S1 connector.


Heated Oxygen Sensor Replacement - Sensor 2

Removal Procedure
Caution: Refer to Heated Oxygen and Oxygen Sensor Caution in the Preface section.
Caution: Do not solder heated oxygen sensor wires. Soldering the wires will result in the loss
of the air reference to the sensor. Refer to Engine Electrical for proper wire and connection
repair techniques.
2. Disconnect the electrical connector.

3. Remove the heated oxygen sensor 2 (HO2S2).

Note: 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 service sensors will already
have the compound applied to the threads. If a sensor is removed from any engine and if for
any reason it is to be reinstalled, the threads must have anti-seize compound applied before
reinstallation.
1. Coat the threads of the HO2S2 with an anti-seize compound, if needed.
2. Install the HO2S2.
Tighten
Tighten the heated oxygen sensor to 42 N·m (31 lb ft).
3. Connect the electrical connector.


Idle Air Control Valve Replacement

Removal Procedure

2. Disconnect the idle air control (IAC) valve connector.
3. Remove the IAC valve retaining bolts.
Caution:
• Do Not push or pull on the IAC valve pintle on IAC valves that have been in service. The
force required to move the pintle may damage the threads on the worm drive.
• Do Not soak the IAC valve in any liquid cleaner or solvent, as damage may result.
4. Remove the IAC valve.

5. Clean the IAC valve O-ring seal area, the pintle valve seat, and the air passage with a
suitable fuel system cleaner. Do not use methyl ethyl ketone.

Note: If installing a new IAC valve, be sure to replace it with an identical part. The IAC valve
pintle shape and diameter are designed for the specific application. Measure the distance
between the tip of the IAC valve pintle and the mounting flange. If the distance is greater
than 28 mm (1.1 in), use finger pressure to slowly retract the pintle.
The force required to retract the pintle will not damage the IAC valve. The purpose of the
28 mm (1.1 in) setting is to prevent the IAC pintle from bottoming out on the pintle seat.
This 28 mm (1.1 in) setting is also an adequate setting for controlled idle on a restart.
1. Lubricate a new O-ring with engine oil. Install the new O-ring onto the valve.
2. Install the IAC valve into the throttle body.

3. Install the IAC valve retaining bolts.
Tighten
Tighten the idle air control valve retaining bolts to 3 N·m (27 lb in).
4. Connect the IAC valve connector.

6. Perform the idle learn procedure. Refer to Idle Learn.

Accelerator Pedal Position Sensor Replacement

Removal Procedure

2. Disconnect the electronic throttle control (ETC) connector from the accelerator pedal.
3. Remove the 3 accelerator pedal retaining nuts.
4. Remove the accelerator pedal.

1. Position the accelerator pedal.
2. Install the 3 accelerator pedal retaining nuts.
Tighten
Tighten the accelerator pedal retaining nuts to 19 N·m (14 lb ft).
3. Connect the ETC connector to the accelerator pedal.


Throttle Body Assembly Replacement

Removal Procedure

2. Disconnect the intake air temperature sensor connector.
3. Remove the air cleaner inlet duct from the throttle body.

4. Disconnect the electronic throttle body connector.

5. Disconnect the coolant hoses from the electronic throttle body.
6. Remove the throttle body retaining bolts.

7. Remove the throttle body and discard the gasket.
Caution: Use care when cleaning the old gasket from the aluminum surfaces in order to
prevent damage to the sealing surfaces.
1. Clean the gasket mating surface on the intake manifold.

Note: If the electronic throttle control valve is removed from the throttle body, the throttle
body may be cleaned in a cold immersion type cleaner. Do not clean the electronic throttle
control valve with any type of solvent or cleaner.
2. Clean the throttle body.

3. Install the electronic throttle body assembly with a new gasket.
4. Install the electronic throttle body retaining nuts and bolts.
Tighten
Tighten the throttle body retaining bolts and nuts to 15 N·m (11 lb ft).
5. Connect the electronic throttle body electrical connector.

6. Install the throttle body coolant hoses.

7. Install the air cleaner inlet duct to the throttle body.

9. Fill the cooling system.

Throttle Body Inspection and Cleaning

Warning: Wear safety glasses when using compressed air in order to prevent eye injury.
1. Remove the throttle body from the vehicle. Refer to Throttle Body Assembly Replacement.
2. Open the throttle valve of the throttle body.

3. Use a solvent soaked cloth to remove dirt or carbon deposits/buildup from the throttle valve
and the throttle bore.
4. Ensure that the throttle valve and throttle bore are clean and dry.
5. Inspect that the throttle valve operates smoothly and freely.
Install the throttle body to the vehicle. Refer to Throttle Body Assembly Replacement.

Fuel Pressure Relief
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.
1. Remove the fuel cap.

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

Fuel Pressure Gage Installation and Removal

Special Tools
J 34730-1A Fuel Pressure Gage
Warning: Gasoline or 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: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
Caution: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
• The fuel pipe connections
• The hose connections
• The areas surrounding the connections
1. Install the J 34730-1A to the fuel pressure connection, located on the fuel rail.
Warning: Do not drain the fuel into an open container. Never store the fuel in an open
container due to the possibility of a fire or an explosion.

2. Place the bleed hose of the fuel pressure gage into an approved gasoline container.
3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the gage.
4. Turn ON the ignition, with the engine OFF.
5. Command the fuel pump ON with a scan tool until all of the air is bled out of the gage.
6. Close the bleed valve on the fuel pressure gage.
7. Command the fuel pump ON with a scan tool.
8. Inspect for fuel leaks.
Removal Procedure
1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve
to bleed fuel system pressure.
2. Place a shop towel under the fuel pressure gage to catch any remaining fuel spillage.
3. Remove the J 34730-1A from fuel pressure connection.
4. Drain any fuel remaining in the fuel pressure gage into an approved container.
5. Install the cap on the fuel pressure connection.
6. Place the shop towel in an approved container.

Fuel Tank Draining

Special Tools
• J 42960-2 Fuel Flapper Door Holder

• J 42960-1 Fuel 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 filler cap.

2. Install the J 42960-2 into the fuel fill pipe in order to hold the door open.
3. Insert the J 42960-1 into the fuel tank until the hose reaches the bottom of the fuel tank.
4. Use an air operated pump device in order to drain as much fuel through the fuel fill pipe as
possible.

Fuel Tank Replacement

Removal Procedure
Warning: Refer to Relieving Fuel Pressure Warning in the Preface section.
1. Relieve the fuel pressure. Refer to Fuel Pressure Relief.

3. Drain the fuel tank.
4. Disconnect the parking brake cable retainer clamps and the support along the fuel tank to
provide clearance for the tank.

5. Remove the fuel tank filler tube clamp at the fuel tank.
6. Disconnect the fuel tank filler tube.
7. Disconnect the fuel tank filler tube at the fuel tank.
8. Disconnect the canister vapor tube at the control valve vapor tube.
9. Disconnect the fuel line near the right front of the fuel tank.
10. Disconnect the wiring harness clips and the fuel line clips as needed.

11. Remove the front exhaust pipe. Refer to Front Pipe Replacement.
12. Support the fuel tank.

13. Remove the fuel tank retaining nuts.
14. Carefully lower the fuel tank.
15. Remove the fuel tank.
16. Transfer any parts as needed.

1. Raise the fuel tank into position.
Caution: Refer to Fuel Tank Strap Fastener Caution in the Preface section.
2. Install the fuel tank mounting straps and bolts.
Tighten
Tighten the fuel tank strap retaining bolts to 20 N·m (15 lb ft).
3. Connect the fuel line.

4. Connect the wiring harness clips and the fuel line clips as needed.
5. Connect the fuel pump electrical connector.
6. Connect the fuel vapor line.
7. Connect the fuel tank filler tube and the fuel tank vent tube.
8. Install the fuel tank filler tube clamp at the fuel tank.
9. Install the front exhaust pipe. Refer to Front Pipe Replacement.

10. Install the parking brake cable retainer clamps and the support.
Tighten
Tighten the parking brake cable retainer clamps to 10 N·m (89 lb in).

12. Fill the fuel tank.
13. Perform a leak check of the fuel tank and the fuel line connections.

Fuel Tank Pressure Sensor Replacement

Removal Procedure
1. Remove the fuel fill cap.

3. Remove the rear seat. Refer to Rear Seat Cushion Replacement.
4. Remove the fuel sender assembly access cover.

5. Disconnect the fuel tank pressure (FTP) sensor electrical connector.

6. Remove the FTP from the fuel sender assembly.
1. Install the FTP sensor to the fuel sender assembly.
2. Connect the FTP sensor electrical connector.

3. Install the fuel pump access cover.

4. Install the rear seat. Refer to Rear Seat Cushion Replacement.
6. Install the fuel fill cap.

Fuel Sender Assembly Replacement
Removal Procedure
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.

2. Remove the fuel pump assembly. Refer to Fuel Pump Replacement.

3. Disconnect the insulator connector.
Note: The wedge may be disconnected with severe force but can be reconnected.
4. Push the terminal wedge (1) in the insulator connector.
5. Remove the fuel level sensor (1) from the sender housing (2).
6. Remove the sender housing.

7. Remove the fuel sender assembly (3).
1. Install the wires (1) into the sender assembly (2).

Note: Ensure the sender assembly and the fuel level sensor are installed properly. If not the
fuel gauge and fuel level warning indicator will not function properly.
2. Install the sender assembly onto the fuel pump assembly (1).
3. Install the fuel level sensor onto the sender housing.
4. Connect the wire into the insulator connector.
5. Connect the insulator connector

6. Install the fuel pump assembly into the fuel tank. Refer to Fuel Pump Replacement.

Fuel Pump Replacement

Removal Procedure


3. Remove the rear seat. Refer to Rear Seat Cushion Replacement.
4. Remove the fuel pump access cover.
5. Disconnect the electrical connector at the fuel pump assembly.

6. Disconnect the fuel line.
7. Remove the fuel pump assembly clip.
8. Remove the fuel pump assembly from the tank.
9. Remove and discard the gasket.

1. Clean the gasket mating surface on the fuel tank.

2. Position the new gasket in place.
3. Install the fuel pump into the fuel tank in the same location as removed for ease of line and
connector installation.
4. Install the fuel pump assembly clip.
5. Connect the fuel pump assembly connector.
6. Install the fuel pump line.
7. Install the fuel pump access cover.
8. Install the EF10 fuse.
10. Perform an operational check of the fuel pump.
11. Install the rear seat. Refer to Rear Seat Cushion Replacement.

Fuel Hose/Pipes Assembly Replacement
Removal Procedure
Warning: 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.
1. Relieve the fuel pressure. Refer to Fuel Pressure Relief.

2. Disconnect the front fuel hose from the fuel rail.

3. Lift and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
4. Disconnect the front fuel hose from the fuel pipe.
5. Disconnect the rear fuel hose from the fuel pipe.

6. Remove the fuel pipe mounting plastic bolt.
7. Remove the fuel pipe mounting screws and cover.

8. Remove the fuel pipe.

9. Remove the fuel pump access cover. Refer to Fuel Sender Assembly Replacement.
10. Disconnect the fuel hose from the fuel pump.

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

12. Remove rear fuel hose.
1. Connect the rear fuel hose.

2. Install the fuel tank. Refer to Fuel Tank Replacement.

3. Install the fuel pump access cover. Refer to Fuel Sender Assembly Replacement.
4. Install the fuel pipe.

5. Install the fuel pipe mounting screws and cover.

6. Install the fuel pipe mounting plastic bolt.
7. Connect the rear fuel hose to the fuel pipe.

8. Connect the front fuel hose to the fuel pipe.

9. Lower the vehicle.
10. Connect the fuel hose to the fuel rail.

11. Connect the negative battery cable, if disconnected.

Fuel Injection Fuel Rail Assembly Replacement
Removal Procedure

3. Remove the engine cover bolts and cover.

4. Disconnect the electronic throttle control connector.

5. Disconnect the intake air temperature sensor.
6. Disconnect the camshaft position sensor.
7. Disconnect the manifold absolute pressure sensor.
8. Disconnect the fuel injector harness connectors.
9. Remove the purge solenoid valve to intake manifold hose.

10. Remove the MAP sensor vacuum hose.
11. Remove the upper intake manifold bracket bolts.
12. Remove the upper intake manifold bracket.

13. Disconnect the fuel feed line.
14. Disconnect the throttle body outlet coolant hose.
Caution:
• Use care when servicing the fuel system components, especially the fuel injector
electrical connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and
the outlet ports of the fuel rail in order to prevent contamination.
• Do not use compressed air to clean the fuel rail assembly as this may damage the fuel
rail components.
• Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to
the fuel rail assembly.

15. Remove the fuel rail mounting bolts.
Caution:
• Use care when servicing the fuel system components, especially the fuel injector
electrical connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and
the outlet ports of the fuel rail in order to prevent contamination.
• Do not use compressed air to clean the fuel rail assembly as this may damage the fuel
rail components.
• Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to
the fuel rail assembly.
Note: If an injector becomes separated from the rail and remains in the cylinder head,
replace the injector O-ring seals and the retaining clip.
16. Remove the fuel rail with the fuel injectors attached.
17. Remove the fuel injector retaining clips.
18. Remove the fuel injectors by pulling down and out.
19. Discard the fuel injector O-rings.

Note: 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 retainer clips onto the fuel injectors and the fuel rail ledge.
4. Make sure that the clip is parallel to the fuel injector harness connector.
5. Install the fuel rail assembly into the cylinder head.

6. Install the fuel rail mounting bolts.
Tighten
Tighten the fuel rail mounting bolts to 25 N·m (18 lb ft).
7. Connect the throttle body coolant hose.
8. Connect the fuel feed hose.
9. Install the intake manifold upper bracket with the bolts.

10. Install the MAP sensor vacuum hose.
11. Install the purge solenoid to intake manifold hose.

12. Connect the fuel injector harness connectors. Rotate each fuel injector as required to avoid
stretching the wiring harness.
13. Connect the MAP sensor connector.
14. Connect the Camshaft position sensor.
15. Connect the intake air temperature sensor.
16. Connect the electronic throttle control connector.
17. Install the engine cover with bolts.

19. Perform a leak check of the fuel rail and fuel injectors.

Evaporative Emission Canister Purge Solenoid Valve

Replacement
Removal Procedure

2. Disconnect the evaporative emission (EVAP) canister purge solenoid connector.
3. Disconnect the vacuum hoses from the EVAP canister purge solenoid.
4. Remove the EVAP canister purge solenoid from the intake manifold.

1. Attach the EVAP canister purge solenoid to the intake manifold.

2. Connect the vacuum hoses to the EVAP canister purge solenoid.
3. Connect the EVAP canister purge solenoid connector.

Evaporative Emission System Hoses/Pipes

Replacement
Removal Procedure
required.
1. Disconnect the evaporative emission (EVAP) canister purge solenoid valve to intake manifold
hose.

2. Remove the EVAP canister front tube from the EVAP canister purge solenoid valve and the
EVAP canister vapor pipe.
3. Disconnect the EVAP canister pipe from the EVAP canister vapor rear tube.

4. Lift and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
5. Remove the EVAP canister vapor pipe plastic bolt and cover.
6. Remove the EVAP canister vapor pipe 4 mounting screws and cover.
7. Remove the EVAP canister vapor pipe.

8. Remove the EVAP canister vapor rear tube clip.

9. Disconnect the EVAP canister vapor rear tube.
10. Remove the EVAP canister purge tube clip.
11. Disconnect the EVAP canister purge tube.
12. Remove the fuel tank. Refer to Fuel Tank Replacement.

13. Remove the rollover valve tube from the fuel tank.

1. Install the rollover valve to the fuel tank.

2. Install the fuel tank. Refer to Fuel Tank Replacement.
3. Connect the EVAP canister purge tube.

4. Install the EVAP canister purge tube clip.
5. Connect the EVAP canister vapor rear tube.
6. Install the EVAP canister vapor rear tube clip.

7. Install the EVAP canister vapor pipe.

8. Install the EVAP canister vapor pipe mounting screws and cover.
9. Install the EVAP canister vapor pipe plastic bolt and cover.

11. Connect the EVAP canister vapor pipe from the EVAP canister vapor rear tube.
12. Connect the EVAP canister front tube from the EVAP canister purge solenoid valve and the
EVAP canister vapor pipe.

13. Connect the EVAP canister purge solenoid valve to intake manifold hose.

Evaporative Emission Canister Vent Solenoid Valve

Replacement
Removal Procedure
required.
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the evaporative emission (EVAP) canister vent solenoid valve bracket bolt.

3. Remove the EVAP canister vent solenoid valve bracket.
4. Disconnect the EVAP canister vent solenoid valve electrical connector.

5. Remove the EVAP canister vent solenoid valve hose clip.
6. Disconnect the EVAP canister vent solenoid valve hoses.
7. Remove the EVAP canister vent solenoid valve.

1. Connect the EVAP canister vent solenoid valve hoses.

2. Install the EVAP canister vent solenoid valve hose clip.
3. Connect the EVAP canister vent solenoid valve electrical connector.
4. Install the EVAP canister vent solenoid valve bracket to the EVAP canister vent solenoid
valve.

5. Install the bolt to the EVAP canister vent solenoid valve bracket.
Tighten
Tighten the EVAP canister vent solenoid valve bracket bolt to 4 N·m (35 lb in).

7. Connect the negative battery cable, if disconnected.

Evaporative Emission Canister Replacement

Removal Procedure
required.
1. Disconnect the canister fuel vapor hoses.

2. Remove the bolt that secures the canister flange to the vehicle.
3. Slide the canister out of the track holder.
4. Remove the canister.

1. Insert the canister into the track and slide it into position.
2. Install the canister flange bolt.
Tighten
Tighten the evaporative emission (EVAP) canister flange bolt to 4 N·m (35 lb in).
3. Connect the canister fuel vapor hoses.

Ignition Coil Replacement

Removal Procedure

2. Disconnect the electronic ignition (EI) system ignition coil connector.
3. Note the ignition wire location and remove the ignition wire.
4. Remove the EI system ignition coil retaining nuts.
5. Remove the EI system ignition coil.

1. Install the EI system ignition coil into the mounting location and install the retaining nuts.
Tighten
Tighten the EI system ignition coil retaining nuts to 10 N·m (89 lb in).
2. Connect the EI system ignition coil connector.


Spark Plug Wire Inspection

Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be
necessary to accurately identify conditions that may affect engine operation. Inspect for the
following conditions:
1. Correct routing of the spark plug wires. Incorrect routing may cause cross-firing.
2. Any signs of cracks or splits in the wires.
3. Inspect each boot for the following conditions:
• Tearing
• Piercing
• Arcing
• Carbon tracking
• Corroded terminal
If corrosion, carbon tracking, or arcing are indicated on a spark plug wire boot or on a terminal,
replace the wire and the component connected to the wire.

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Spark Plug Wire Replacement

Removal Procedure
1. Turn OFF the ignition.
2. Remove the engine cover from the engine.
3. Disconnect the spark plug wire (1) at each spark plug.

• Twist each spark plug boot 1/2 turn before removing.
• Pull only on the boot or use a tool designed for this purpose in order to remove the wire

from each spark plug.

4. Disconnect the spark plug wire from the coil (2).
• Twist each spark plug boot 1/2 turn before removing.
• Pull only on the boot or use a tool designed for this purpose in order to remove the wires
from the coil.
1. Install the spark plug wire on the coil (2).

2. Install the spark plug wire (1) at each spark plug.
Caution: If the boot to wire movement has occurred, the boot will give a false visual
impression of being fully seated. Ensure that the boots have been properly assembled by
pushing sideways on the installed boots. Failure to properly seat the terminal onto the spark
plug will lead to wire core erosion and result in an engine misfire or crossfire condition, and
possible internal damage to the engine.
3. Inspect the wires for proper installation:

• Push down on each boot in order to inspect the seating.
• Reinstall any loose boot.
• Wire routing must be kept intact during service and followed exactly when wires have
been disconnected or when replacement of the wires is necessary. Failure to route the
wires correctly can lead to radio interference and crossfire of the plugs, or shorting of the
leads to the ground.
• Any time the spark plug wires or boots are installed on the spark plugs, new dielectric
grease needs to be applied inside the boot.

4. Install the engine cover on the engine.
Tighten
Tighten the engine cover bolts to 3 N·m (31 lb in).

Spark Plug Inspection

Spark Plug Usage
• Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability
conditions.
• 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
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.

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.
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).

4. Inspect (3) for evidence of improper arcing.

• Measure the gap between the center electrode (4) and the side electrode (3) terminals.
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.
- A rattling sound indicates internal damage.
- 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.
5. 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
• Normal operation--Brown to grayish-tan with small amounts of white powdery deposits are
normal combustion by-products from fuels with additives.
• 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

Removal Procedure
Caution: Observe the following service precautions:

• Allow the engine to cool before removing the spark plugs. Attempting to remove spark plugs
from a hot engine can cause the spark plugs to seize. This can damage the cylinder head
threads.
• Clean the spark plug recess area before removing the spark plug. Failure to do so can result
in engine damage due to dirt or foreign material entering the cylinder head, or in
contamination of the cylinder head threads. Contaminated threads may prevent proper
seating of the new spark plug.
• Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are
either hotter or colder than those specified for the vehicle. Installing spark plugs of another
type can severely damage the engine.
2. Loosen the 4 bolts and remove the engine cover.

3. Remove the spark plug wires from the spark plugs. Refer to Spark Plug Wire Replacement.
4. Remove the spark plugs from the engine.
Caution: It is important to check the gap of all new and reconditioned spark plugs before
installation. Pre-set gaps may have changed during handling. Use a round wire feeler gauge
to be sure of an accurate check, particularly on used plugs. Installing plugs with the wrong
gap can cause poor engine performance and may even damage the engine.
1. Gap the spark plugs to the specifications. Refer to Ignition System Specifications.

Caution: Be sure plug threads smoothly into cylinder head and is fully seated. Use a thread
chaser if necessary to clean threads in cylinder head. Cross-threading or failing to fully seat
spark plug can cause overheating of plug, exhaust blow-by, or thread damage. Follow the
recommended torque specifications carefully. Over or under-tightening can also cause severe
damage to engine or spark plug.
2. Install the spark plugs to the engine.
Tighten
Tighten the spark plugs to 25 N·m (18 lb ft).
3. Install the spark plug wires to the spark plugs. Refer to Spark Plug Wire Replacement.
4. Install the engine cover and tighten the 4 bolts.
Tighten
Tighten the engine cover bolts to 3 N·m (31 lb in).

Crankshaft Position Sensor Replacement

Removal Procedure

2. Disconnect the crankshaft position (CKP) sensor electrical connector.
3. Remove the CKP sensor bolt.


4. Remove the CKP sensor.
1. Install the CKP sensor with the bolt.
Tighten
Tighten the CKP sensor bolt to 6.5 N·m (58 lb in).

2. Connect the CKP sensor electrical connector.


Camshaft Position Sensor Replacement

Removal Procedure

2. Remove the engine cover bolts and the nuts.
3. Remove the engine cover.

4. Disconnect the camshaft position (CMP) sensor electrical connector.

5. Remove the timing belt front cover. Refer to Timing Belt Replacement.
1. Install the CMP sensor and bolt.
Tighten
Tighten the CMP sensor bolts to 7 N·m (62 lb in).

2. Install the timing bolt front cover. Refer to Timing Belt Replacement.
3. Connect the CMP sensor electrical connector.
4. Install the engine cover.

Rough Road Sensor Replacement

Removal Procedure

2. Disconnect the rough road sensor electrical connector and remove the rough road sensor.

1. Install the rough road sensor and connect the electrical connector.

Knock Sensor Replacement

Removal Procedure

2. Remove the intake manifold bracket bolts and bracket.
3. Disconnect the knock©sensor (KS) electrical connector.

2010 General Motors Corporation. All rights reserved.

4. Remove the Knock sensor bolt.

5. Remove the knock sensor.
1. Install the KS with the bolt.
Tighten
Tighten the KS bolt to 20 N·m (15 lb ft).
2. Connect the KS electrical connector.

3. Install the intake manifold bracket and bolts.
Tighten
• Tighten the bracket upper bolt to 25 N·m (18 lb ft).
• Tighten the bracket lower bolt to 45 N·m (33 lb ft).

Exhaust Gas Recirculation Valve Replacement

Removal Procedure

2. Disconnect the electrical exhaust gas recirculation (EGR) valve electrical connector.
3. Remove the EGR valve retaining bolts.
4. Remove the EGR valve.

1. Install the EGR valve with the bolts.
Tighten
Tighten the electrical EGR valve retaining bolts to 30 N·m (22 lb ft).
2. Connect the EGR valve electrical connector.


Exhaust Gas Recirculation Valve Pipe Replacement

Removal Procedure
1. Remove the exhaust gas recirculation (EGR) pipe mounting bolts from the intake manifold.
2. Remove the EGR pipe mounting bolts from the EGR valve.
3. Raise and suitable support the vehicle. Refer to Lifting and Jacking the Vehicle.

4. Remove the lower mounting bolt attaching the EGR pipe to the intake manifold.
5. Remove the EGR pipe.
1. Install the EGR pipe and the lower bolt attaching the EGR pipe to the intake manifold.
Tighten
Tighten the EGR pipe mounting bolt to 12 N·m (106 lb in).

2. Install the EGR pipe mounting bolts to the EGR valve.
Tighten
Tighten the EGR pipe to EGR valve mounting bolts to 10 N·m (89 lb in).
4. Install the EGR pipe mounting bolts to the intake manifold.
Tighten
Tighten the EGR pipe to intake manifold mounting bolts to 12 N·m (106 lb in).

Intake Manifold Tuning Valve Actuator Solenoid

Replacement
Removal Procedure

2. Disconnect the intake manifold tuning (IMT) valve solenoid (2) connector.
3. Disconnect the vacuum hoses from the IMT valve solenoid (2).
4. Remove the IMT valve solenoid (2).

1. Install the IMT valve solenoid.

2. Connect the vacuum hoses to the IMT valve solenoid (2).
3. Connect the IMT valve solenoid (2) connector.

Intake Manifold Tuning Valve Actuator Replacement

Removal Procedure
1. Disconnect the vacuum hose from the intake manifold tuning (IMT) valve actuator valve.
Note: Ensure the IMT valve is closed before removing the IMT valve actuator retaining bolts
and valve.
2. Remove the IMT valve actuator valve bolts.

3. Remove the IMT valve actuator valve from the IMT valve.

1. Install the IMT valve actuator valve to the IMT valve.
2. Install the IMT valve actuator valve bolts.
Tighten
Tighten the IMT valve actuator valve retaining bolts to 12 N·m (106 lb ft).
3. Connect the vacuum hose to the IMT valve actuator valve.

Intake Air Tuning Valve Vacuum Reservoir

Replacement
Removal Procedure
1. Remove the vacuum hoses from the intake manifold (IMT) vacuum reservoir (1).
2. Remove the IMT valve reservoir (1).

1. Install the IMT valve reservoir (1).

2. Install the vacuum hoses to the IMT valve reservoir (1).

Air Cleaner Inlet Duct Replacement

Removal Procedure
Note: The intake air temperature sensor is no longer replaced as a separate service item. If
the intake air temperature sensor is faulty, replacement of the entire air cleaner inlet duct
will be necessary.

2. Disconnect the electrical connector from the intake air temperature (IAT) sensor.
3. Disconnect the breather tube from the air cleaner intake duct.
4. Loosen the clamps securing the air cleaner intake duct.

5. Remove air cleaner intake duct.

Note: An improperly installed air cleaner intake duct or breather tube will cause incorrect
sensor readings resulting in MIL illumination or a drivability concern.
1. Install the air cleaner intake duct.
2. Tighten the clamps securing the air cleaner intake duct.
Tighten
Tighten the clamp to 3 N·m (27 lb in).
3. Connect the breather tube to the air cleaner intake duct.

4. Connect the electrical connector to the IAT sensor.

Air Cleaner Element Replacement

Removal Procedure
1. Loosen the air cleaner intake duct clamp at the air cleaner assembly.
2. Remove the air cleaner intake duct from the upper air cleaner cover.
3. Remove the upper air cleaner screws.
4. Remove the upper air cleaner cover from the lower air cleaner housing.
5. Remove the air cleaner filter from lower air cleaner housing.
1. Install the air cleaner filter into the lower air cleaner housing.
2. Install the upper air cleaner cover to lower air cleaner housing.
3. Install the upper air cleaner screws.
Tighten
Tighten the upper air cleaner cover screws to 3 N·m (27 lb in).
4. Install the intake duct to the upper air cleaner cover.
Tighten
Tighten the intake duct clamp to 3 N·m (27 lb in).

Air Cleaner Assembly Replacement

Removal Procedure
1. Loosen the air cleaner intake duct clamp at the air cleaner assembly.
2. Remove the air cleaner intake duct from the air cleaner assembly.
3. Remove the air cleaner assembly attachment bolts.

4. Remove the air cleaner assembly.
1. Install the air cleaner assembly.

2. Install the air cleaner assembly attachment bolts.
Tighten
Tighten the nut to 10 N·m (89 lb in).
3. Install the air cleaner intake duct to the air cleaner assembly.
Tighten
Tighten the air cleaner intake duct clamp to 3 N·m (27 lb in).


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Temperature Versus Resistance

© 2010 General Motors Corporation. All rights reserved.

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Altitude Versus Barometric Pressure

© 2010 General Motors Corporation. All rights reserved.

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Ignition System Specifications

© 2010 General Motors Corporation. All rights reserved.

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Fastener Tightening Specifications

© 2010 General Motors Corporation. All rights reserved.

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Emission Hose Routing Diagram

© 2010 General Motors Corporation. All rights reserved.

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Evaporative Emissions Hose Routing Diagram

(1) Intake Manifold

© 2010 General Motors Corporation. All rights reserved.

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Fuel Hose/Pipes Routing Diagram

(1) Fuel Tank

© 2010 General Motors Corporation. All rights reserved.

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Engine Control Module Replacement

Warning: Refer to Battery Disconnect Warning in the Preface section.

1. Disconnect the negative battery cable.

3. Remove the ECM retaining nuts.

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4. Remove the ECM from the ECM mount.

1. Position the ECM in place.

Caution: Refer to Fastener Caution in the Preface section.

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3. Connect the ECM connectors.

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Crankshaft Position System Variation Learn

Vehicle must remain in Park or Neutral.

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• Hold throttle while fuel cut-off occurs.

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• The throttle body assembly is replaced

1.Turn the ignition ON.

© 2010 General Motors Corporation. All rights reserved.

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Engine Coolant Temperature Sensor Replacement

1. Relieve the coolant system pressure.

Warning: Refer to Battery Disconnect Warning in the Preface section.

2. Disconnect the negative battery cable.

5. Remove the ECT sensor.

Caution: Refer to Fastener Caution in the Preface section.

© 2010 General Motors Corporation. All rights reserved.

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1. Install the ECT sensor.

2. Connect the ECT sensor connector.

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Manifold Absolute Pressure Sensor Replacement

Warning: Refer to Battery Disconnect Warning in the Preface section.

1. Disconnect the negative battery cable.

Caution: Refer to Fastener Caution in the Preface section.