Kit Installation Procedure
Kit Installation Procedure1. Some MY2004 vehicles may have a radio security code. Refer to Service Bulletin 04-00-89-007. Record radio station presets for reprogramming at the end of this procedure.
CAUTION:
Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before serviceing any electrical components. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or it's components.
CAUTION:
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and stem under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.
2. Disconnect the negative battery cable.
3. Remove the coolant surge tank cap and engine oil filler cap in order to remove inner pressure.
4. Drain the Coolant by separating the upper radiator hose from the thermostat housing (1).
5. Remove the clamp from the air cleaner outlet duct at the throttle body.
5.1. Disconnect the electrical connector from the intake air temperature (IAT) sensor (1).
5.2. Disconnect the breather tube (2) from the crankcase ventilation tube.
5.3. Remove clamp from the air cleaner outlet duct at air cleaner and remove the intake duct (3).
6. Disconnect the idle air control (IAC) connector (1).
7. Disconnect the throttle position (TP) sensor connector (1).
8. Disconnect the throttle cable(s) (1) by opening the throttle and moving the cable through the release slot. Refer to Throttle Body Cable Removal, Installation and Adjustment Procedure in this bulletin.
9. Remove the engine cover (1). Refer to Engine Cover Replacement in SI.
10. Disconnect the coolant return hose (1) from the surge tank.
11. Remove the nylon strap (1) which holds the PCV valve to the coolant return hose. Separate the PCV hose from the PCV valve and remove the coolant return hose from the throttle body.
12. Remove the old coolant return hose and retain the protective webbing sleeve (1) for use later in the procedure. Un-strap ABS tests connector (if equipped) from the coolant surge tank side.
13. Remove the coolant inlet hose from the throttle body (1) and pull away from the throttle body and from the top of the timing cover. The other end will be removed later.
14. Remove the throttle body. (Retain nuts for step 16).
15. Unscrew the old PCV valve (1) from the cam cover and discard.
16. Install the old throttle body nuts (1) to a stud bolt and tighten/jam both nuts together.
Once the nuts are jammed together turn counterclockwise to remove the stud bolt (1). Repeat the process for the other stud bolts then discard all three stud bolts.
17. Disconnect and remove the MAP sensor (1) from the intake manifold.
17.1. Disconnect the MAP sensor wiring harness connector (2).
17.2. Save the old Map sensor (1). The MAP sensor will be re-installed to a new location later in this service procedure.
18. Remove the MAP sensor vacuum hose (1), EVAP canister purge solenoid vacuum hose (2) and rubber plug (3) from intake manifold. Discard (1) and (3).
CAUTION:
Extreme care must be taken not to damage the intake manifold port when using the reamer tool.
IMPORTANT:
Special Tool EN-48981 Reamer and the Brass Sleeve are required for this procedure. Your Dealership should have received the reamer by Mid-October 2007 (SPX-Kent Moore) and the brass sleeve in November 2007.
19. Use GM Special Tool EN-48981 Reamer and Brass Sleeve Tool to enlarge the lower port of the intake manifold from 4 mm to 6 mm (1).
Prior to starting the reaming procedure on the intake manifold port, ensure that the intake manifold is at shop temperature.
IMPORTANT:
Take you time reaming the port and do not push down hard or force the tool through the port. Excess force could result in cracking the intake manifold port during the reaming.
20. Insert a clean rag inside the intake manifold throttle body bore to prevent any debris and burrs from falling inside the intake manifold.
21. Place the brass sleeve tool over the lower intake manifold port (1) and press down to seat. This will prevent the port from cracking during the reaming operation. Before starting, refer to the following tips on using the reamer with brass sleeve.
IMPORTANT:
Lubricating the reamer tool with windshield washer fluid may ease the cutting process.
21.1. Lubricate the reamer tool EN-48981 (2) with windshield washer fluid, then insert and turn the tool clockwise while applying a very slight downward pressure, and slowly working the tool back and forth as required.
21.2. Remove the tool (2) while exerting a slight upwards motion while maintaining a clockwise rotation. While working the tool out, hold the brass sleeve (1) in place to prevent losing it. Clean the tool and lubricate it with windshield washer fluid, then re-insert the tool in the port and continue reaming. Repeat as required.
21.3. Once the tool (2) has bottomed out, continue turning the tool in a clockwise rotation while exerting a slight upwards motion to release the reamer.
21.4. Remove the brass sleeve from the port (1).
IMPORTANT:
Retain Special Tool EN-48981 Reamer and the Brass Sleeve for the next Product Safety Bulletin 07047 to be performed.
IMPORTANT:
If the intake manifold requires replacing due to damage caused by the reaming process (1) the new intake manifold MAP sensor vacuum port may also require reaming to 6 mm using the reaming operation outlined in this bulletin.
22. Using a utility knife or equivalent carefully remove any burrs from the inside of the intake manifold throttle body bore (1). Remove the rag and ensure that the bore is free of debris.
23. Remove and discard the stud bolt closest to the throttle body from the intake manifold (1) and save the plastic retainer. Refer to steps 16 and 16.1 in this bulletin for the removal of the stud bolt.
24. Install the new MAP sensor bracket part number (p/n) 96891920, old retainer (5) and new bolt/screw (3) p/n 94500414. Ensure that the larger slot of the retainer is at the bottom when installed as shown above (5).
Tighten
Tighten the MAP sensor bracket bolt/screw (3) to 10-12 Nm (90 lb in).
25. Install the Evap hose to the middle vacuum port on the intake manifold and connect the hose to the retainer as shown above (5).
IMPORTANT:
The MAP sensor hose and bracket position (1) is critical. The hose should not contact the MAP sensor bracket (see above).
26. Install the MAP sensor on the new MAP sensor bracket (2) and connect the MAP sensor wiring harness connector. The MAP sensor connector should be oriented at a 5 o'clock position relative to the Intake Manifold, with the harness positioned toward the front of the vehicle as shown above (4).
Tighten
Tighten the MAP sensor bolt/screw (2) to 10-12 Nm (90 lb in).
27. Install the MAP sensor vacuum tube assembly (1) p/n 96891995 (1) between the lower port on the intake manifold to the underside of the MAP sensor. Ensure that the hose is oriented with the paint mark toward the intake manifold. Install the rubber plug p/n 96351328 on the remaining open intake manifold port.
28. Secure the MAP sensor engine wire harness to the intake manifold bracket using a nylon tie strap (1) Ensure that the MAP sensor wire harness is not secured too tightly, and allow some room for movement. Use p/n 96224564 nylon tie strap.
29. Apply Teflon tape to the new PCV Valve Threads. Install the new PCV valve (1) p/n 96892257 into the cam cover and ensure that the pipes are in a horizontal plane.
30. Install the PCV hose p/n 96892258 (1) to the throttle body adapter and then install the other end marked with paint facing up to the PCV valve (2).
31. Install the throttle body adapter p/n 96875543.
32. Install 4 bolts/screws p/n 94500751 to secure the throttle body adapter to the intake manifold. Install the copper washer (gasket) p/n 96892557 (1) provided in the kit under the right upper bolt.
Tighten
Tighten the four throttle body adapter bolts/screws to 10-12 Nm (90 lb in)
33. Install the throttle body hose assembly coolant outlet return hose (1) p/n 96887046 from the PCV valve, ensuring that the paint mark is facing up and connected toward the PCV valve assembly, and connect the other end to the surge tank. Re-install the tie strap for the ABS Test Connector (if equipped) to the side of the coolant surge tank.
34. Install the throttle body assembly (1), p/n 96889775 on the throttle body adapter, using the four throttle body bolts/screws p/n 94500411.
Tighten
Tighten the four throttle body adapter bolts/screws to 10-12 Nm (90 lb in).
IMPORTANT:
The routing of the throttle body coolant hose is very critical.
35. Connect the throttle body hose assembly short coolant inlet hose p/n 96887047 to the throttle body (1).
IMPORTANT:
The picture above is for illustration purposes only. The intent is to show the correct routing of the coolant hoses with the paint mark facing upwards and connected at the PCV valve assembly.
36. The coolant hoses shown must have the white paint marks (1) at the PCV valve assembly.
37. Install the protective webbing sleeve (1) over the coolant inlet hose p/n 96887049 close to the foam insulator. (See Part Number on the hose, which is part of the breather assembly 96892215). Install black electrical tape to the ends of the webbing sleeve in order to keep in the correct position.
38. Connect the coolant inlet hose p/n 96887049 (See Part Number on the hose, which is part of breather assembly 96892215) to the rear throttle body port (1).
39. Connect the IAC valve and TPS wiring harness connectors to the throttle body assembly.
Ensure both connectors are fully engaged by lightly pulling on them.
40. Position the new coolant inlet hose (1) p/n 96887048 (See Part Number on the hose, which is part of breather assembly 96892215) on top of the timing belt cover in place of the old hose. The new coolant inlet hose should be positioned under the power steering pipe.
41. Remove and discard the old coolant inlet hose from the thermostat housing and connect the new coolant inlet hose (1). Use long-nose pliers to remove and install the spring clamp.
42. Install the upper radiator hose to the thermostat housing (1).
43. Remove the upper intake manifold accelerator cable clamp from the intake manifold and move it to the old MAP sensor location (1).
44. Install the accelerator cable clamp 180 degrees from the original position as shown (1), and tighten the bolt.
Tighten
Tighten the accelerator cable clamp bolt to 10-12 Nm (90 lb in).
45. Install the new accelerator cable bracket p/n 96875545 as shown to the intake manifold. Ensure that the bracket retaining plate is positioned as shown (1) with the rounded corner oriented upwards and the depression oriented toward the bolt head. The retaining plate should not protrude beyond the intake mounting tab. This is critical for proper throttle cable alignment and operation.
Tighten
Tighten the accelerator cable bracket bolt to 10-12 Nm (90 lb in).
46. Install the accelerator cable to the newly positioned intake manifold bracket/clamp and then to the throttle body. If equipped, install the cruise control cable. Check for correct throttle opening and closing positions by operating the accelerator pedal. Make sure that the throttle valve reaches wide open throttle position (1). If it does not, inspect for coolant hose spring clip contact with the throttle body accelerator cable cam.
47. Adjust the throttle cable. Refer to the Throttle Cable Adjustment Service Procedure in this Bulletin.
48. Install the new Air Cleaner Outlet Duct (1) p/n 96889507 between the throttle body and air cleaner assembly, and tighten the clamps.
Install the IAT sensor connector. Ensure proper connection by lightly pulling on the connector.
49. Connect the breather assembly hose p/n 96892215 to the PCV valve and to the new air cleaner outlet duct. Secure the hose to the base of the PCV valve (1) on the cam cover, and attach it with a spring clamp.
50. Check for the correct throttle opening and closing positions by operating the accelerator pedal. Make sure that the throttle valve reaches wide open throttle position (1). If it does not, inspect for the following:
Coolant hose spring clip contact with the throttle body accelerator cable cam.
51. Remove the EGR electrical connector.
52. Remove the lower crankcase external ventilation hose clamp (1).
53. Remove the external ventilation hose from the crankcase pipe and fold the hose away from the pipe.
IMPORTANT:
When handling the fiberglass crankcase breather tube insulation sleeve you may want to wear gloves.
54. Install the crankcase breather tube insulator sleeve p/n 96941983 (1) over the external ventilation pipe assembly while working out any wrinkles and pushing the insulator down completely toward the engine crankcase.
55. Push the crankcase breather tube insulator sleeve down far enough to expose the top two inches of the crankcase vent pipe. Install the spring clip (ear type) clamp p/n 94530682 over the vent hose and install the rubber vent hose over the vent pipe, and then crimp the spring clamp on to the rubber hose (1).
CAUTION:
To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle while the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end the components are being removed and strap the vehicle to the hoist.
56. Raise the vehicle. Refer to Lifting and Jacking the vehicle in SI.
IMPORTANT:
Make sure that the insulator sleeve is bottomed out against the engine block.
57. Verify that the insulator sleeve is bottomed out against the engine block (1).
58. Lower the vehicle.
IMPORTANT:
The worm clamp should be installed toward the back of the valve cover with the clamp screw (1) positioned up so that the engine cover will install properly.
59. Slide the excess insulator sleeve up over the external ventilation hose as shown.
Open the worm clamp (1) p/n 94530121. Install and secure the clamp around the external ventilation hose.
60. Install the EGR electrical connector.
61. Install the engine cover, coolant surge tank cap and engine oil filler cap.
62. Top off the coolant. Refer to SI for the Cooling System Draining and Filling Procedure.
63. Install the battery negative cable.
64. Perform the following idle relearn procedure:
64.1. Turn the ignition ON.
64.2. Turn the ignition OFF for 15 seconds.
64.3. Turn the ignition ON for 5 seconds.
64.4. Turn the ignition OFF for 15 seconds.
64.5. Start the engine in park/neutral.
64.6. Allow the engine to run until the engine coolant is above 85°C (185°F).
64.7. Turn the A/C ON for 10 seconds, if equipped.
64.8. If the vehicle is equipped with an automatic transaxle, apply the parking brake. While pressing the brake pedal, place the transaxle in D (drive) for 10 seconds.
64.9. Turn the A/C OFF for 10 seconds, if equipped.
64.10. If the vehicle is equipped with an automatic transaxle, while pressing the brake pedal, place the transaxle in park/neutral.
64.11. Turn the ignition OFF. The idle learn procedure is now complete.
65. Road test the vehicle with a Tech 2(R) Scan Tool.
66. Reset the clock and radio stations.