Transcript
Document ID: 2047020
2009 Pontiac Solstice
Page 1 of 1
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Specifications | Document ID: 2047020
Temperature Versus Resistance (ECT) °C
°F
OHMS
Temperature vs Resistance Values (Approximate) 150
302
47
140
284
60
130
266
77
120
248
100
110
230
132
100
212
177
90
194
241
80
176
332
70
158
467
60
140
667
50
122
973
45
113
1188
40
104
1459
35
95
1802
30
86
2238
25
77
2796
20
68
3520
15
59
4450
10
50
5670
5
41
7280
0
32
9420
-5
23
12300
-10
14
16180
-15
5
21450
-20
-4
28680
-30
-22
52700
-40
-40
100700
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Document ID: 2047023
2009 Pontiac Solstice
Page 1 of 1
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Specifications | Document ID: 2047023
Temperature Versus Resistance (IAT 1) °C
°F
OHMS
Temperature vs Resistance Values (Approximate) 150
302
64
144
291
72
138
280
81
132
269
92
126
258
104
120
248
119
114
237
136
108
226
156
102
215
181
96
204
209
90
194
245
84
183
286
78
172
338
72
161
400
66
150
477
60
140
572
55
131
689
49
120
840
43
109
1030
37
98
1271
31
87
1580
25
77
1978
19
66
2509
13
55
3218
7
44
4164
1
33
5439
-4
+24
7169
-10
+14
9590
-16
+3
13089
-22
-7
18078
-28
-18
25284
-34
-29
35832
-40
-40
51499
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Document ID: 2047024
2009 Pontiac Solstice
Page 1 of 2
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Specifications | Document ID: 2047024
Temperature Versus Resistance (IAT 2) °C
°F
OHMS
Temperature vs Resistance Values (Approximate) -40
-40
48977
-35
-31
36528
-30
-22
27503
-25
-13
20899
-20
-4
16026
-15
+5
12388
-10
+14
9654
-5
+23
7584
0
32
5995
5
41
4776
10
50
3829
15
59
3090
20
68
2510
25
77
2051
30
86
1685
35
95
1392
40
104
1156
45
113
965
50
122
809
55
131
682
60
140
577
65
149
491
70
158
419
75
167
359
80
176
309
85
185
267
90
194
231
95
203
201
100
212
176
105
221
154
110
230
135
115
239
119
120
248
105
125
257
93
266
83
130
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Document ID: 2047024
Page 2 of 2
135
275
74
140
284
66
145
293
59
150
302
53
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Document ID: 839729
2009 Pontiac Solstice
Page 1 of 1
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Specifications | Document ID: 839729
Altitude Versus Barometric Pressure Altitude Measured in Meters (m)
Altitude Measured in Feet (ft)
Barometric Pressure Measured in 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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Document ID: 1884319
2009 Pontiac Solstice
Page 1 of 1
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Specifications | Document ID: 1884319
Ignition System Specifications Specification Application
Metric
Ignition Type
Coil-On-Plug
Firing Order Spark Plug Torque Spark Plug Gap
English 1-3-4-2
17-23 N·m
12.5-17 lb ft
0.9-0.75 mm
0.035-0.030 in
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Document ID: 1828438
2009 Pontiac Solstice
Page 1 of 2
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Specifications | Document ID: 1828438
Fastener Tightening Specifications Specification Application
Metric
English
Accelerator Pedal Position (APP) Sensor Nut
10 N·m
89 lb in
Air Cleaner Front Bolt/Nut
10 N·m
89 lb in
4 N·m
35 lb in
Air Inlet Screen Support Nut
10 N·m
89 lb in
Brake Pipe
20 N·m
15 lb ft
Camshaft Position Actuator Solenoid Valve Bolt
10 N·m
89 lb in
Camshaft Position (CMP) Sensor Bolt
10 N·m
89 lb in
Charge Air Cooler Bolt
9 N·m
80 lb in
Charge Air Cooler Hose Clamp
6 N·m
53 lb in
Charge Air Cooler Pipe Clamp
5 N·m
44 lb in
Charge Air Cooler Pipe Bolt
7 N·m
62 lb in
Charge Air Cooler Rear Bracket Nut
9 N·m
80 lb in
Charge Air Bypass Solenoid Bolt
10 N·m
89 lb in
Crankshaft Position (CKP) Sensor Bolt
10 N·m
89 lb in
Engine Coolant Temperature (ECT) Sensor
20 N·m
15 lb ft
Evaporative Emission (EVAP) Canister Purge Solenoid Bolt
10 N·m
89 lb in
Fuel Feed Pipe Bolt
10 N·m
89 lb in
Fuel Feed Pipe Fitting
30 N·m
22 lb ft
Fuel Fill Hose Clamp
4.5 N·m
40 lb in
9 N·m
80 lb in
Fuel Fill Pipe to Housing Bolt
1.5 N·m
13 lb in
Fuel Injector Fuel Rail Fuel Pressure Sensor
33 N·m
25 lb ft
Fuel Pump Module Access Cover Bolt
10 N·m
89 lb in
Fuel Rail Bolt
22 N·m
16 lb ft
Fuel Tank Strap/Support Bolt
25 N·m
18 lb ft
Heated Oxygen Sensor (HO2S)
42 N·m
31 lb ft
High Pressure Fuel Feed Pipe Fitting
32 N·m
24 lb ft
High Pressure Fuel Pump Cover Bolt
10 N·m
89 lb in
High Pressure Fuel Pump Bolt
15 N·m
11 lb ft
Ignition Coil Bolt
10 N·m
89 lb in
9 N·m
80 lb in
Knock Sensor
25 N·m
18 lb ft
Manifold Absolute Pressure (MAP) Sensor Bolt
10 N·m
89 lb in
Mass Air Flow (MAF) Sensor Screw
0.6 N·m
5 lb in
Spark Plug
20 N·m
15 lb ft
Air Cleaner Outlet Duct Clamp
Fuel Fill Pipe Ground Strap Bolt
Intake Air Pressure and Temperature Sensor Bolt
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Throttle Body Bolt
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10 N·m
89 lb in
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Document ID: 1829018
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Schematic and Routing Diagrams | Document ID: 1829018
2009 Pontiac Solstice
Evaporative Emissions Hose Routing Diagram
(1) Fuel Tank Pressure (FTP) Sensor (2) Fuel Tank (3) Evaporative Emission (EVAP) Vent Solenoid Valve (4) EVAP Canister (5) Purge Flow Check Valve (6) EVAP Purge Solenoid Valve (7) Fill Limit Vent Valve (FLVV) (8) Grade Vent Valve
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Document ID: 1911250
2009 Pontiac Solstice
Page 1 of 2
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 1911250
Throttle Learn Description The engine control module (ECM) learns the idle position of the throttle plate to ensure the correct idle. The learned airflow values are stored within the ECM. These values are learned to adjust for production variation and will continuously learn during the life of the vehicle to compensate for reduced airflow due to coking. Anytime the throttle body airflow rate changes, for example due to cleaning or replacing, the values must be relearned. A vehicle that had a heavily coked throttle body that has been cleaned or replaced may take several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability to reset all learned values back to zero. A new ECM will also have values set to zero. The idle may be unstable or a DTC may set if the learned values do not match the actual airflow.
Conditions for Running the Throttle Learn Procedure • DTCs P0101, P0102, P0103, P0107, P0108, P0111, P0112, P0113, P0506, and P0507 are not set. • The engine speed is between 450-4,000 RPM. • The manifold absolute pressure (MAP) is greater than 5 kPa. • The mass air flow (MAF) is greater than 2 g/s. • The ignition 1 voltage is greater than 10 volts.
Throttle Learn With Scan Tool-Reset 1. Ignition ON, engine OFF. With a scan tool, perform the Idle Learn Reset in Module Setup. 2. Start the engine, monitor the TB Idle Airflow Compensation parameter. The TB Idle Airflow Compensation parameter value should equal 0 percent and the engine should be idling at a normal idle speed. ⇒ If the engine is not idling normally, proceed with the Learn portion of the diagnostic. 3. Clear the DTCs and return to the diagnostic that referred you here.
Without Scan Tool-Learn Important: Do NOT perform the Without Scan Tool-Learn procedure if DTCs are set. Refer to Diagnostic Trouble Code (DTC) List - Vehicle. 1. 2. 3. 4. 5. 6.
The engine speed is between 450-4,000 RPM. The manifold absolute pressure (MAP) is greater than 5 kPa. The mass air flow (MAF) is greater than 2 g/s. The ignition 1 voltage is greater than 10 volts. Start and idle the engine in Park for 3 minutes. With a scan tool, monitor desired and actual RPM.
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7. The ECM will start to learn the new idle cells and Desired RPM should start to decrease. 8. Ignition OFF for 60 seconds. 9. Start and idle the engine in Park for 3 minutes. Important: During the drive cycle the check engine light may come on with idle speed DTCs. If idle speed codes are set, clear codes so the ECM can continue to learn. 10. After the 3 minute run time the engine should be idling normal. ⇒ If the engine idle speed has not been learned the vehicle will need to be driven at speeds above 70 km/h (44 mph) with several decelerations and extended idles. 11. After the drive cycle, the engine should be idling normally. ⇒ If the engine idle speed has not been learned, turn OFF the ignition for 60 seconds and repeat step 6. 12. Once the engine speed has returned to normal, clear DTCs.
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Document ID: 2157385
2009 Pontiac Solstice
Page 1 of 3
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2157385
Engine Control Module Replacement Warning: Replacement or reprogramming of the ECM, or replacement of the clutch pedal position sensor (CPPS) or clutch pedal requires that a CPPS learn procedure be performed. Failure to perform the CPPS learn procedure may result in personal injury or damage to the vehicle or its components if the vehicle is in gear and the starter motor is accidentally engaged. Caution: • Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. • Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. • In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. • Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. • The replacement control module must be programmed. Note: It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last engine oil change.
Removal Procedure
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1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 2. Record the preset radio stations. 3. Turn the ignition OFF. 4. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. 5. Remove the left front fender. Refer to Front Fender Replacement. 6. Remove the windshield washer solvent container. Refer to Windshield Washer Solvent Container Replacement. 7. Release the engine control module (ECM) bracket upper and lower retaining tabs (1, 2) using a small screwdriver or other suitable tool. 8. Remove the ECM from the bracket by lifting upward after releasing the tabs.
9. Disconnect the engine wiring harness electrical connectors (1, 3) from the ECM (2).
Installation Procedure
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1. Connect the engine wiring harness electrical connectors (1, 3) to the ECM (2).
2. Slide the ECM into the bracket. 3. Push down on the ECM until the upper and lower retaining tabs (1, 2) snaps into place. 4. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. 5. Install the windshield washer solvent container. Refer to Windshield Washer Solvent Container Replacement. 6. Install the left front fender. Refer to Front Fender Replacement. 7. Reset the clock and preset radio stations. 8. If a NEW ECM was installed, the ECM must be programmed. Refer to Control Module References. 9. If equipped with a manual transmission, perform the clutch pedal position sensor learn procedure. Refer to Clutch Pedal Position Sensor Learn.
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Document ID: 2101697
2009 Pontiac Solstice
Page 1 of 2
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101697
Engine Coolant Temperature Sensor Replacement Removal Procedure
1. Partially drain the cooling system. Refer to Cooling System Draining and Filling. 2. Remove the heat shield from the around the electrical connector, if necessary. 3. Disconnect the engine wiring harness electrical connector (3) from the engine coolant temperature (ECT) sensor.
4. Remove the ECT.
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Installation Procedure Caution: Refer to Fastener Caution in the Preface section.
1. Install the ECT and tighten to 20 N·m (15 lb ft).
2. Connect the engine wiring harness electrical connector (3) to the ECT sensor. 3. Install the heat shield around the electrical connector, if necessary. 4. Fill the cooling system as needed. Refer to Cooling System Draining and Filling.
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Document ID: 2101699
2009 Pontiac Solstice
Page 1 of 2
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101699
Mass Airflow Sensor Replacement Removal Procedure
1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF) sensor.
2. Remove the MAF sensor screws. 3. Remove the MAF sensor. © 2010 General Motors Corporation. All rights reserved.
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Installation Procedure Caution: Refer to Fastener Caution in the Preface section.
1. Install the MAF sensor. 2. Install the MAF sensor screws and tighten to 0.6 N·m (5 lb in).
3. Connect the engine wiring harness electrical connector (1) to the MAF sensor.
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Document ID: 2101703
2009 Pontiac Solstice
Page 1 of 2
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101703
Manifold Absolute Pressure Sensor Replacement Removal Procedure
1. Disconnect the engine wiring harness electrical connector (2) from the manifold absolute pressure (MAP) sensor.
2. Remove the MAP sensor bolts. 3. Remove the MAP sensor and O-ring seal from the intake manifold. © 2010 General Motors Corporation. All rights reserved.
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Installation Procedure
1. Lubricate the O-ring seal with clean engine oil. 2. Install the MAP sensor to the intake manifold. Caution: Refer to Fastener Caution in the Preface section. 3. Install the MAP sensor bolts and tighten to 10 N·m (89 lb in).
4. Connect the engine wiring harness electrical connector (2) to the MAP sensor.
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Document ID: 2101705
2009 Pontiac Solstice
Page 1 of 3
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101705
Heated Oxygen Sensor Replacement - Sensor 1 Special Tools J 39194 Oxygen Sensor Wrench
Removal Procedure Caution: The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail connector could affect proper operation of the oxygen sensor. Caution: The use of excessive force may damage the threads in the exhaust manifold/pipe. Note: • The in-line connector and louvered end must be kept clear of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the heated oxygen sensor (HO2S). • The HO2S may be difficult to remove when the engine temperature is less than 48°C (120°F).
1. Open the hood. 2. Remove the connector position assurance (CPA) retainer. 3. Disconnect the engine wiring harness electrical connector (1) from the HO2S electrical connector (3). 4. Remove the HO2S electrical connector clip (2) from the camshaft cover.
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5. Using the J 39194 , remove the position 1 HO2S.
Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The 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 have the compound applied to the threads. If a sensor is removed and is to be reinstalled, the threads must have an anti-seize compound applied before installation. Caution: Refer to Fastener Caution in the Preface section.
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1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953 or equivalent. 2. Using the J 39194 , install the position 1 HO2S and tighten to 42 N·m (31 lb ft).
3. Connect the engine wiring harness electrical connector (1) to the HO2S electrical connector (3). 4. Install the HO2S electrical connector clip (2) to the camshaft cover. 5. Install the CPA retainer. 6. Close the hood.
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Document ID: 2101708
2009 Pontiac Solstice
Page 1 of 3
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101708
Heated Oxygen Sensor Replacement - Sensor 2 Special Tools J 39194 Oxygen Sensor Wrench
Removal Procedure Caution: The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail connector could affect proper operation of the oxygen sensor. Caution: The use of excessive force may damage the threads in the exhaust manifold/pipe. Caution: Refer to Heated Oxygen Sensor Resistance Learn Reset Caution in the Preface section. Note: The in-line connector and louvered end must be kept clear of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the heated oxygen sensor (HO2S). Note: The HO2S may be difficult to remove when the engine temperature is less than 48°C (120° F).
1. Open the hood. 2. Remove the connector position assurance (CPA) retainer. 3. Disconnect the HO2S electrical connector (4) from the engine wiring harness electrical connector (2). 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. © 2010 General Motors Corporation. All rights reserved.
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5. Using the J 39194 , remove the position 2 HO2S.
Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The 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 already have the compound applied to the threads. If the sensor is removed and is to be reinstalled, the threads must be coated with an anti-seize compound before reinstallation.
1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953 or equivalent.
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2. Using the J 39194 , install the position 2 HO2S and tighten to 42 N·m (31 lb ft). 3. Lower the vehicle.
4. Connect the HO2S electrical connector (4) to the engine wiring harness electrical connector (2). 5. Install the CPA retainer. 6. Close the hood.
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Document ID: 2101711
2009 Pontiac Solstice
Page 1 of 2
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101711
Accelerator Pedal Position Sensor Replacement Removal Procedure
1. Remove the knee bolster. Refer to Knee Bolster Replacement. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector.
3. Remove the APP sensor nuts. 4. Remove the APP sensor from the vehicle. © 2010 General Motors Corporation. All rights reserved.
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Installation Procedure
1. Install the APP sensor to the vehicle. Caution: Refer to Fastener Caution in the Preface section. 2. Install the APP sensor nuts and tighten to 10 N·m (89 lb in).
3. 4. 5. 6.
Connect the APP sensor electrical connector. Confirm that the APP sensor connector locking clip is fully secured. Verify the operation of the accelerator pedal. Install the knee bolster. Refer to Knee Bolster Replacement.
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Document ID: 2101714
2009 Pontiac Solstice
Page 1 of 4
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101714
Throttle Body Assembly Replacement Removal Procedure Caution: Do not use solvent of any type when cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as damage to the gasket surfaces and throttle body assembly may result. Use care in cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as sharp tools may damage the gasket surfaces. Caution: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components.
1. Remove the charge air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement. 2. Disconnect the engine wiring harness electrical connector (1) from the electronic throttle control (ETC).
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3. Disconnect the engine wiring harness electrical connector (1) from the brake booster auxiliary pump. 4. Remove the brake booster auxiliary pump electrical connector clip from the bracket.
5. Remove the throttle body bolts. 6. Remove the throttle body and seal from the intake manifold.
Installation Procedure
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1. Inspect the throttle body seal, and replace if necessary. Caution: Refer to Fastener Caution in the Preface section. 2. Position the throttle body to the intake manifold. 3. Install the throttle body bolts and tighten to 10 N·m (89 lb in).
4. Connect the engine wiring harness electrical connector (1) to the brake booster auxiliary pump. 5. Install the brake booster auxiliary pump electrical connector clip to the bracket.
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6. Connect the engine wiring harness electrical connector (1) to the ETC. 7. Install the charge air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement.
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Document ID: 2101731
2009 Pontiac Solstice
Page 1 of 1
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101731
Throttle Body Cleaning Caution: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate. Caution: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components. 1. Remove the throttle body. Refer to Throttle Body Assembly Replacement. 2. Inspect the throttle body bore and the throttle valve plate for deposits. You must open the throttle valve in order to inspect all of the surfaces. 3. Clean the throttle body bore and the throttle valve plate using a clean shop towel with GM Top Engine Cleaner P/N 1052626 (Canadian P/N 993026) or AC-Delco Carburetor Tune-up Conditioner P/N X66-P, or an equivalent product. 4. Install the throttle body. Refer to Throttle Body Assembly Replacement.
© 2010 General Motors Corporation. All rights reserved.
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Document ID: 2157387
2009 Pontiac Solstice
Page 1 of 2
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2157387
Fuel Pressure Relief (Low Pressure Side with CH 48027-100) Tools Required CH-48027-100 Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning in the Preface section. 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 engine cover, if required. 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the fuel rail service port cap. 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. 4. 5. 6. 7.
Wrap a shop towel around the fuel service port. Connect the CH-48027-3 (3) to the fuel service port. Connect the CH-48027-2 (2) to the CH-48027-3 (3). Place the hose on the©CH-48027-2 (2) into an approved gasoline container. 2010 General Motors Corporation. All rights reserved.
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8. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 9. Close the valve on the CH-48027-2 (2). 10. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 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 Note: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 11. Disconnect the CH-48027-2 (2) from the CH-48027-3 (3). 12. Disconnect the CH-48027-3 (3) from the fuel service port. 13. Remove the shop towel from around the fuel service port, and place in an approved gasoline container. 14. Install the fuel service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap.
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Document ID: 2101746
2009 Pontiac Solstice
Page 1 of 1
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101746
Fuel Pressure Relief (High Pressure Side) Warning: Fuel that flows out at high pressure can cause serious injury to the skin and eyes. ALWAYS depressurize the fuel system before removing components that are under high fuel pressure. 1. Install a scan tool to the vehicle and command the fuel pump relay OFF, allowing the low pressure fuel pump to shut off. 2. Start the vehicle and allow the engine to idle until the engine stops. The engine will stop in approximately 20-30 seconds. 3. Turn the ignition OFF. 4. Using the scan tool, verify that there is little to no fuel pressure, if there still is fuel pressure repeat step 2. Note: If a scan tool is not available, WAIT at LEAST 2 hours after the engine has been run, before removing the high pressure fuel line. 5. Remove the high pressure fuel line. Refer to Fuel Feed Intermediate Pipe Replacement.
© 2010 General Motors Corporation. All rights reserved.
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Document ID: 2101742
2009 Pontiac Solstice
Page 1 of 1
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101742
Fuel Pressure Relief (Low Pressure without Special Tool) Warning: Refer to Gasoline/Gasoline Vapors Warning in the Preface section. 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. 2. 3. 4. 5. 6. 7. 8.
Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. Remove the engine cover, if required. Remove the fuel service port cap. Wrap a shop towel around the fuel service port and using a small flat bladed tool, depress (open) the fuel rail test port valve. Remove the shop towel from around the fuel service port, and place in an approved gasoline container. Install the fuel service port cap. Install the engine cover, if required. Tighten the fuel fill cap.
© 2010 General Motors Corporation. All rights reserved.
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Document ID: 2101736
2009 Pontiac Solstice
Page 1 of 2
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101736
Fuel Pressure Relief (Low Pressure with CH 48027) Special Tools CH-48027 Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning in the Preface section. 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 engine cover, if required. 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the fuel service port cap. 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. 4. 5. 6. 7. 8.
Wrap a shop towel around the fuel service port. Connect the CH-48027-3 (4) to the fuel service port. Connect the CH-48027-2 (2) to the CH-48027-3 (4). Place the hose on the CH-48027-2 (2) into an approved gasoline container. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. © 2010 General Motors Corporation. All rights reserved.
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9. Close the valve on the CH-48027-2 (2). 10. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 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 Note: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 11. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 12. Disconnect the CH-48027-3 (4) from the fuel service port. 13. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 14. Install the fuel service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap.
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Document ID: 2157391
2009 Pontiac Solstice
Page 1 of 2
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2157391
Fuel Pressure Gage Installation and Removal (With CH 48027-100) Special Tools CH-48027-100 Digital Pressure Gage
Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning in the Preface section. 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. Relieve the fuel system pressure. Refer to Fuel Pressure Relief. 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027-100 , refer to the manufacture's directions.
Removal Procedure © 2010 General Motors Corporation. All rights reserved.
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1. Relieve the fuel system pressure, if required. Perform the following steps: 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. 1.1. Wrap a shop towel around the fuel rail service port. 1.2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 1.3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 1.4. Close the valve on the CH-48027-2 (2). 1.5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 1.6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 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 2. 3. 4. 5. 6. 7.
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). Disconnect the CH-48027-2 (2) from the CH-48027-3 (3). Disconnect the CH-48027-3 (3) from the fuel rail service port. Install the fuel rail service port cap. Install the engine cover, if required. Tighten the fuel fill cap.
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Document ID: 2157389
2009 Pontiac Solstice
Page 1 of 2
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2157389
Fuel Pressure Gage Installation and Removal (With CH 48027) Special Tools CH-48027 Digital Pressure Gage
Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning in the Preface section. 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. Relieve the fuel system pressure. Refer to Fuel Pressure Relief. 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's directions.
Removal Procedure © 2010 General Motors Corporation. All rights reserved.
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1. Relieve the fuel system pressure, if required. Perform the following steps: 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. 1.1. Wrap a shop towel around the fuel rail service port. 1.2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 1.3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 1.4. Close the valve on the CH-48027-2 (2). 1.5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 1.6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 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 2. 3. 4. 5. 6. 7.
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). Disconnect the CH-48027-3 (4) from the fuel rail service port. Install the fuel rail service port cap. Install the engine cover, if required. Tighten the fuel fill cap.
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Document ID: 2101756
2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101756
Metal Collar Quick Connect Fitting Service Special Tool J 37088-A Fuel Line Disconnect Tool Set
Removal Procedure
1. Relieve the low side fuel system pressure. Refer to the Fuel Pressure Relief. 2. Remove the retainer from the quick-connect fitting.
© 2010 General Motors Corporation. All rights reserved.
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Warning: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 3. Blow dirt out of the fitting using compressed air.
4. Choose the correct tool from the J 37088-A for the size of the fitting. Insert the tool into the female connector, then push inward in order to release the locking tabs.
5. Pull the connection apart. Caution: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a
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radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required. 6. Use a clean shop towel in order to wipe off the male pipe end. 7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required.
Installation Procedure
Warning: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 1. Apply a few drops of clean engine oil to the male pipe end.
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2. Push both sides of the fitting together in order to snap the retaining tabs into place.
3. Once installed, pull on both sides of the fitting in order to make sure the connection is secure.
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4. Install the retainer to the quick-connect fitting.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101761
Plastic Collar Quick Connect Fitting Service Removal Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning in the Preface section.
Note: There are several types of plastic collar fuel and evaporative emission quick connect fittings that may be used on this vehicle. • Bartholomew (1) • Q release (2) • Squeeze to release (3) • Sliding retainer (4) • Push down TI (5) The following instructions apply to all of these types of fittings except where indicated. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
© 2010 General Motors Corporation. All rights reserved.
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Warning: Wear safety glasses when using compressed air in order to prevent eye injury. 2. Using compressed air, blow any dirt out of the quick connect fitting.
3. This step applies to the Bartholomew style connectors ONLY. Squeeze the plastic quick connect fitting release tabs.
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4. This step applies to Q release style connector ONLY. Release the fitting by pushing the tab toward the other side of the slot in the fitting.
5. This step applies the Squeeze to release style connectors ONLY. Squeeze where indicated by arrows on both sides of the plastic ring surrounding the quick connect fitting.
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6. This step also, applies to the Squeeze to release style connectors ONLY. Squeeze where indicated by the arrows on both sides of the plastic ring surrounding the quick connect fitting.
7. This step applies the Sliding retainer style connectors ONLY. Release the fitting by pressing on one side of the release tab causing it to push in slightly. If the tab does not move, try pressing the tab in from the opposite side. The tab will only move in one direction.
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8. This step applies to the Push down TI style connectors ONLY. Release the fitting by pressing on the tab indicated by the arrow. Warning: Refer to Relieving Fuel Pressure Warning in the Preface section.
9. Pull the connection apart. Caution: Use an emery cloth in order to remove rust or burrs from the fuel pipe. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. 10. Wipe off the male pipe end using a clean shop towel. 11. Inspect both ends of the fitting for dirt and burrs.
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12. Clean or replace the components as required.
Installation Procedure Warning: Refer to Fuel Pipe Fitting Warning in the Preface section.
1. Apply a few drops of clean engine oil to the male connection end.
2. Push both sides of the quick-connect fitting together in order to cause the retaining feature to snap into place.
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3. Once installed, pull on both sides of the quick connect fitting in order to make sure the connection is secure.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101763
Fuel Tank Draining Special Tools • J 36850 Transjel Lubricant • J 42960-2 Fuel Flapper Door Holder • J 45004 Fuel Tank Drain Hose Warning: Never drain or store fuel in an open container. Always use an approved fuel storage container in order to reduce the chance of fire or explosion. Warning: Place a dry chemical (Class B) fire extinguisher nearby before performing any on-vehicle service procedures. Failure to follow these precautions may result in personal injury. 1. Remove the fuel fill cap.
2. Install the J 42960-2 into the fuel fill pipe in order to hold the door open. Note: Lubricate the fuel drain hose with J 36850 or equivalent to aid in hose insertion. Do not use an unapproved lubricant. 3. Insert the J 45004 into the fuel tank until the hose reaches the bottom of the fuel tank. 4. Use a hand or air operated pump device in order to drain as much fuel through the fuel fill pipe as possible.
© 2010 General Motors Corporation. All rights reserved.
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Document ID: 2101765
2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101765
Fuel Tank Replacement Removal Procedure Caution: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief. Note: Ensure that the fuel tank is completely drained because of the severe angle that the tank will need to be tipped, in order to remove the tank. 2. Drain the fuel tank. Refer to Fuel Tank Draining. 3. Remove the rear compartment trim panel. Refer to Rear Compartment Trim Panel Replacement.
4. Remove the fuel pump module access cover bolts. 5. Remove the fuel pump module access cover.
© 2010 General Motors Corporation. All rights reserved.
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6. Disconnect the fuel sending unit electrical connector (3). 7. Disconnect the fuel tank pressure sensor electrical connector (5). 8. Disconnect the evaporative emission (EVAP) canister vent solenoid electrical connector (2).
9. Disconnect the fuel pump fuel feed line quick connect fitting (1) from the module. Refer to Plastic Collar Quick Connect Fitting Service. 10. Disconnect the EVAP canister purge line quick connect fitting (2) from the module. Refer to Plastic Collar Quick Connect Fitting Service. 11. Secure the fuel feed and EVAP purge lines up out of the way.
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12. Remove the fuel fill pipe. Refer to Fuel Tank Filler Pipe Replacement. 13. Disconnect the fuel tank fill pipe EVAP line quick connect fitting (1) from the module. Refer to Plastic Collar Quick Connect Fitting Service. 14. Remove the fuel tank fill EVAP line out through the access hole in order to prevent damage to the pipe when removing the tank. 15. Remove the rear suspension crossmember. Refer to Rear Suspension Support Crossmember Replacement. 16. Remove the stabilizer shaft. Refer to Stabilizer Shaft Replacement. 17. Position an adjustable jack under the fuel tank.
18. Remove the fuel tank strap/support bolts (2). 19. Remove the fuel tank support bolts (3). 20. Remove the fuel tank supports (1).
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21. Remove the adjustable jack from under the fuel tank and with the aid of an assistant, tilt the tank down towards the left side of the vehicle and carefully remove the tank. 22. Place the fuel tank onto a suitable work surface. 23. Cap or plug the fuel feed and EVAP lines in order to prevent fuel loss and/or system contamination.
24. If the fuel tank is being replaced, perform the following: • Disconnect and remove the EVAP line (1). Refer to Plastic Collar Quick Connect Fitting Service. • Remove the EVAP canister. Refer to Evaporative Emission Canister Replacement. • Remove the fuel pump module. Refer to Fuel Pump Module Replacement.
Installation Procedure
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1. If the fuel tank was replaced, perform the following: • Install the fuel pump module. Refer to Fuel Pump Module Replacement. • Install the EVAP canister. Refer to Evaporative Emission Canister Replacement. • Install and connect the EVAP line (1). Refer to Plastic Collar Quick Connect Fitting Service.
2. Remove the caps or plugs from the fuel feed and EVAP lines. 3. With the aid of an assistant tilt the tank up and carefully install the tank in from the left side of the vehicle. 4. Position an adjustable jack under the fuel tank. Caution: Refer to Fastener Caution in the Preface section.
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5. Position the fuel tank supports (1). 6. Install the fuel tank strap/support bolts (2) and tighten to 22 N·m (16 lb ft). 7. Install the fuel tank support bolts (3) and tighten to 22 N·m (16 lb ft).
8. Remove adjustable jack from under the fuel tank. 9. Install the stabilizer shaft. Refer to Stabilizer Shaft Replacement. 10. Install the rear suspension crossmember. Refer to Rear Suspension Support Crossmember Replacement. 11. Install the fuel tank fill EVAP line in through the access hole. 12. Connect the fuel tank fill pipe EVAP line quick connect fitting (1) to the module. Refer to Plastic Collar Quick Connect Fitting Service. 13. Install the fuel fill pipe. Refer to Fuel Tank Filler Pipe Replacement.
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14. Unsecure the fuel feed and EVAP purge lines and position to the module. 15. Connect the EVAP canister purge line quick connect fitting (2) to the module. Refer to Plastic Collar Quick Connect Fitting Service. 16. Connect the fuel pump fuel feed line quick connect fitting (1) to the module. Refer to Plastic Collar Quick Connect Fitting Service.
17. Connect the EVAP canister vent solenoid electrical connector (2). 18. Connect the fuel tank pressure sensor electrical connector (5). 19. Connect the fuel sending unit electrical connector (3).
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20. Install the pump module access cover. 21. Install the fuel pump module access cover bolts and tighten to 10 N·m (89 lb in). 22. Install the rear compartment trim panel. Refer to Rear Compartment Trim Panel Replacement. 23. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. 24. Inspect for leaks using the following procedures: 24.1. Turn ON the ignition, with the engine OFF for 2 seconds. 24.2. Turn OFF the ignition for 10 seconds. 24.3. Turn ON the ignition, with the engine OFF. 24.4. Inspect for fuel leaks.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101769
Fuel Tank Pressure Sensor Replacement Removal Procedure Caution: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages. 1. Remove the rear compartment trim panel. Refer to Rear Compartment Trim Panel Replacement.
2. Remove the fuel pump module access cover bolts. 3. Remove the access cover.
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4. Disconnect the fuel tank pressure sensor electrical connector (5).
5. Remove the fuel tank pressure sensor (2).
Installation Procedure
1. Install the fuel tank pressure sensor (2).
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2. Connect the fuel tank pressure sensor electrical connector (5). Caution: Refer to Fastener Caution in the Preface section.
3. Install the fuel pump module access cover. 4. Install the access cover bolts and tighten to 10 N·m (89 lb in). 5. Install the rear compartment trim panel. Refer to Rear Compartment Trim Panel Replacement.
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Document ID: 2156181
2009 Pontiac Solstice
Page 1 of 3
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2156181
Fuel Level Sensor Replacement Removal Procedure Warning: Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a trunk. To reduce the risk of fire and increased exposure to vapors: • Use forced air ventilation such as a fan set outside of the trunk. • Plug or cap any fuel system openings in order to reduce fuel vapor formation. • Clean up any spilled fuel immediately. • Avoid sparks and any source of ignition. • Use signs to alert others in the work area that fuel system work is in process.
1. Remove the fuel pump module. Refer to Fuel Pump Module Replacement. 2. Using two flat bladed tools, carefully pull both locking tabs (1) outward while simultaneously lifting the level sensor.
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3. Using a small bladed tool, push in the electrical terminals (1) while simultaneously pulling out.
Installation Procedure
1. Push in the electrical terminals (1). Ensure that the electrical terminals attach to the outside holes. 2. Gently tug on the wires to ensure that the terminals are seated and locked into position.
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3. Carefully insert the level sensor until the locking tabs (1) snap into the locked position. 4. Ensure that the level sensor wires are not pinched between the module and sensor. 5. Install the fuel pump module. Refer to Fuel Pump Module Replacement.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101774
Fuel Pump Module Replacement Special Tools J 45722 Fuel Sender Lock Ring Wrench
Removal Procedure Warning: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. Caution: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages. 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Relieve the fuel system pressure. Refer to Fuel Pressure Relief. 2. Remove the rear compartment trim panel. Refer to Rear Compartment Trim Panel Replacement.
3. Remove the fuel pump module access cover bolts. 4. Remove the access cover.
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5. Disconnect the fuel sender electrical connector (3). 6. Disconnect the fuel pressure sensor electrical connector (5).
7. Disconnect the fuel fill pipe evaporative emission (EVAP) pipe quick connect fitting (1). Refer to Plastic Collar Quick Connect Fitting Service. 8. Disconnect the fuel feed pipe quick connect fitting (1). Refer to Plastic Collar Quick Connect Fitting Service.
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Caution: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Caution: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. Note: • The fuel sender assembly may spring up from its position. • When removing the fuel sender assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. It must be tipped slightly during removal to avoid damage to the float. Discard the fuel sender assembly O-ring and replace it with a new one. • Carefully discard the fuel in the reservoir bucket into an approved container. Note: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 9. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. Turn the fuel sender lock ring in a counterclockwise direction.
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10. Raise the fuel sender up slightly. 11. Connect the large EVAP canister quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service. 12. Remove the fuel sender assembly. 13. Remove and discard the fuel sender O-ring.
Note: • Some lock ring were manufactured with DO NOT REUSE stamped into them. These lock rings may be reused if they are not damaged or warped. • Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. • Check the lock ring for flatness.
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14. Place the lock ring on a flat surface. Measure the clearance between to lock ring and the flat surface using a feeler gage at 7 points. 15. If the warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 16. If the warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.
Installation Procedure
1. Install a NEW fuel sender O-ring. 2. Install the fuel sender assembly.
Note: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. Do not apply any type of lubrication in the seal groove.
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Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 3. Using the J 45722 , rotate the fuel sender assembly lock ring clockwise until the ring is locked into place on the fuel tank. 4. Connect the large EVAP canister quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service.
5. Connect the fuel feed pipe quick connect fitting (1). Refer to Plastic Collar Quick Connect Fitting Service. 6. Connect the fuel fill pipe EVAP pipe quick connect fitting (1). Refer to Plastic Collar Quick Connect Fitting Service.
7. Connect the fuel pressure sensor electrical connector (5). 8. Connect the fuel sender electrical connector (3).
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9. Install the access cover. 10. Install the fuel pump module access cover bolts and tighten to 10 N·m (89 lb in). 11. Install the rear compartment trim panel. Refer to Rear Compartment Trim Panel Replacement. 12. Refill the tank. 13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection 14. Inspect for fuel leaks through the following steps: 14.1. Turn the ignition to the ON position for 2 seconds. 14.2. Turn the ignition to the OFF position for 10 seconds. 14.3. Turn the ignition to the ON position. 14.4. Check for fuel leaks.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101776
Fuel Tank Filler Pipe Replacement Removal Procedure Caution: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages. 1. Remove the rear compartment trim panel. Refer to Rear Compartment Trim Panel Replacement.
2. Remove the fuel pump module access cover bolts. 3. Remove the fuel pump module access cover.
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4. Remove the fuel fill pipe housing bolts. 5. Remove the fuel fill pipe housing. 6. Remove the rear wheelhouse liner. Refer to Rear Wheelhouse Panel Liner Replacement.
7. Remove the fill pipe ground strap bolt (2). 8. Disconnect the fuel tank fill evaporative emission (EVAP) line quick connect fitting (3). Refer to Plastic Collar Quick Connect Fitting Service. 9. Loosen the fuel fill pipe hose clamp (1) at the fuel tank. 10. Separate and remove the fuel fill pipe hose assembly. 11. Cover or plug the fuel tank opening and the EVAP line in order to prevent fuel loss and/or system contamination.
Installation Procedure
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1. Remove the cover and/or plug from the fuel tank opening and the EVAP line. 2. Install the fuel fill pipe hose assembly. Caution: Refer to Fastener Caution in the Preface section. 3. Tighten the fuel fill pipe hose clamp (1) at the fuel tank to 4.5 N·m (40 lb in). 4. Connect the fuel tank fill EVAP line quick connect fitting (3). Refer to Plastic Collar Quick Connect Fitting Service. 5. Install the fill pipe ground strap bolt (2) and tighten to 9 N·m (80 lb in).
6. Install the rear wheelhouse liner. Refer to Rear Wheelhouse Panel Liner Replacement. 7. Install the fuel fill pipe housing. 8. Install the fuel fill pipe housing bolts and tighten to 1.5 N·m (13 lb in).
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9. Install the pump module access cover. 10. Install the fuel pump module access cover bolts and tighten to 10 N·m (89 lb in). 11. Install the rear compartment trim panel. Refer to Rear Compartment Trim Panel Replacement.
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Document ID: 2101778
2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101778
Fuel Hose/Pipes Replacement - Chassis Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief. 3. Disconnect the evaporative emission (EVAP) pipe (2) quick connect fitting from the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service. 4. Disconnect the fuel feed pipe (1) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service. 5. Cap or plug the fuel feed pipe, fuel rail and EVAP line to in order to system prevent contamination. 6. Remove the fuel feed and evaporative emission (EVAP) pipe clip from the coolant tube bracket.
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7. Ensure that the area around the brake pipe connections is free of dirt and/or debris. 8. Remove the brake pipes from the brake pressure modulator valve (BPMV), if equipped.
9. Remove the brake pipes from the proportioning valve, if equipped. 10. Cap or plug the BPMV or the proportioning valve in order to prevent system contamination. 11. Remove the fuel tank. Refer to Fuel Tank Replacement.
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12. Remove the brake hose clips (2) from both the right and left brake hose brackets. 13. Remove the right and left brake pipes (1) from the brake hoses.
14. Remove the pipe clips (1) from the following: • Rear suspension lower control arm bracket • Left side brace floor panel tunnel
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15. Remove the pipe clips (1) from the following: • Floor panel number 4 cross bar • Rear carrier bracket • Right side brace floor panel tunnel 16. Remove the pipe clip (2) from the floor panel rear reinforcement. 17. Have an assistant support the fuel feed, EVAP, and brake pipe assembly.
18. 19. 20. 21. 22.
Remove the pipe clip (1) from the underbody side rail. Remove the pipe clip (2) from the floor panel tunnel brace stud. Remove the pipe clip (3) from the floor panel tunnel brace stud. Remove the pipe clips (4) from the floor panel studs. Remove the fuel feed, EVAP, and brake pipe assembly from the vehicle and place on a suitable work surface.
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23. Disconnect the fuel pump fuel feed line (5) from the fuel feed line. Refer to Plastic Collar Quick Connect Fitting Service. 24. Remove the retaining clip (1) from the lines. 25. Open the clips (4 and 7), and remove the fuel feed line (2) from the clips. 26. Inspect and replace and damaged clips.
Installation Procedure
1. Install the fuel feed line (2) to the clips and close the clips (4 and 7). 2. Install the retaining clip (1) to the lines. 3. Connect the fuel pump fuel feed line (5) to the fuel feed line. Refer to Plastic Collar Quick Connect Fitting Service.
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4. With the aid of an assistant, install the fuel feed, EVAP, and brake pipe assembly to the vehicle. 5. Install the pipe clips (4) to the floor panel studs. 6. Install the pipe clip (3) to the floor panel tunnel brace stud. 7. Install the pipe clip (2) to the floor panel tunnel brace stud. 8. Install the pipe clip (1) to the underbody side rail.
9. Install the pipe clip (2) to the floor panel rear reinforcement. 10. Install the pipe clips (1) from the following: • Floor panel number 4 cross bar • Rear carrier bracket • Right side brace floor panel tunnel
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11. Install the pipe clips (1) to the following: • Rear suspension lower control arm bracket • Left side brace floor panel tunnel
12. Install the right and left brake pipes (1) to the brake hoses. 13. Install the brake hose clips (2) to both the right and left brake hose brackets.
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14. Install the fuel tank. Refer to Fuel Tank Replacement. 15. Remove the cap or plug from the BPMV or the proportioning valve. Caution: Refer to Fastener Caution in the Preface section. 16. Install the brake pipes to the proportioning valve, if equipped, and tighten to 20 N·m (15 lb ft).
17. Install the brake pipes to the BPMV, if equipped and tighten to 20 N·m (15 lb ft).
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18. Install the fuel feed and EVAP pipe clip to the coolant tube bracket. 19. Remove the cap or plug from the fuel feed pipe, fuel rail and EVAP line. 20. Connect the fuel feed pipe (1) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service. 21. Connect the EVAP pipe (2) to the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service. 22. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. 23. Inspect for fuel leaks using the following procedure: 23.1. Turn ON the ignition, with the engine OFF for 2 seconds. 23.2. Turn OFF the ignition for 10 seconds. 23.3. Turn ON the ignition, with the engine OFF. 23.4. Inspect for fuel leaks.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 1828876
Fuel Pump Fuel Feed Hose Replacement Removal Procedure
1. Remove the fuel tank. Refer to Fuel Tank Replacement. 2. Disconnect the fuel pump fuel feed line quick connect fitting (2) from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service. 3. Remove the fuel pump fuel feed line.
Installation Procedure
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1. Install the fuel pump fuel feed line. 2. Connect the fuel pump fuel feed line quick connect fitting (2) to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service. 3. Install the fuel tank. Refer to Fuel Tank Replacement.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 1828877
Fuel System Cleaning Important: If the fuel filter is plugged, the fuel tank should be inspected internally and cleaned if necessary. 1. Remove the fuel tank. Refer to Fuel Tank Replacement . 2. Remove the fuel pump module assembly. Refer to Fuel Pump Module Replacement . 3. Inspect the fuel pump module strainer. Replace the pump module assembly if the fuel strainer is contaminated. Important: When flushing the fuel tank, handle the fuel and water mixture as a hazardous material. Handle the fuel and water in accordance with all applicable local, state, and federal laws and regulations. 4. Flush the fuel tank with hot water. 5. Pour the water out of the fuel sender assembly opening in the fuel tank. Rock the fuel tank in order to be sure that the removal of the water from the fuel tank is complete. 6. Allow the tank to dry completely before reassembly. 7. Disconnect the fuel feed pipe at the engine fuel rail. Refer to Metal Collar Quick Connect Fitting Service . Important: Only use oil-free compressed air to blow out the fuel pipes. 8. Clean the fuel pipes by applying air pressure in the opposite direction of the fuel flow. 9. Connect the fuel feed pipe to the engine fuel rail. Refer to Metal Collar Quick Connect Fitting Service . 10. Install the fuel pump module assembly. Refer to Fuel Pump Module Replacement . 11. Install the fuel tank. Refer to Fuel Tank Replacement .
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101803
Fuel Feed Pipe Replacement Removal Procedure
1. Relieve the low side fuel system pressure. Refer to Fuel Pressure Relief. 2. Disconnect the fuel feed line quick connect fitting (1) from the fuel feed pipe. Refer to Metal Collar Quick Connect Fitting Service.
3. Loosen the fuel feed pipe fitting to the high pressure fuel pump. 4. Remove the fuel feed pipe bolts.
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5. 6. 7. 8.
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Remove the fuel feed pipe from the intake manifold. Inspect the fuel feed pipe nut for damaged threads. Inspect the fuel feed pipe sealing bail for damage or debris. Replace the fuel feed pipe if any damage is found.
Installation Procedure
1. Ensure that the fuel feed pipe and fuel pump fittings are clean prior to assembly. 2. Lubricate the fuel feed pipe and the high pressure fuel pump fittings with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent. 3. Position the fuel feed pipe onto the intake manifold. 4. Install the fuel feed pipe fitting to the high pressure fuel pump hand tight. Caution: Refer to Fastener Caution in the Preface section. 5. Install the fuel feed pipe bolts. • Tighten the bolts to 10 N·m (89 lb in). • Tighten the fitting to 30 N·m (22 lb ft).
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6. Connect the fuel feed line quick connect fitting (1) to the fuel feed pipe. Refer to Metal Collar Quick Connect Fitting Service. 7. Inspect for leaks using the following procedure: 7.1. Turn ON the ignition, with the engine OFF for 2 seconds. 7.2. Turn OFF the ignition, for 10 seconds. 7.3. Turn ON the ignition, with the engine OFF. 7.4. Inspect for fuel leaks. 8. Install the low side fuel pressure service port cap. 9. Tighten the fuel fill cap.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101780
Fuel Feed Intermediate Pipe Replacement Removal Procedure
1. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement. 2. Remove the air inlet screen support nuts and support.
3. Relieve the high side fuel system pressure. Refer to Fuel Pressure Relief. 4. Disconnect the engine©wiring harness electrical connector (1) from the high pressure fuel 2010 General Motors Corporation. All rights reserved.
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pump. 5. Remove the engine wiring harness clip (3) from the high pressure fuel pump cover.
6. Remove the high pressure fuel pump cover bolts. 7. Remove the high pressure fuel pump cover.
8. Remove the high pressure fuel pump insulator.
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9. Loosen the high pressure fuel pipe fitting at the fuel pump. 10. Loosen the high pressure fuel pipe fitting at the fuel rail. 11. Remove and discard the high pressure fuel pipe.
Installation Procedure
1. Ensure that the high pressure fuel pump, and fuel rail fittings are clean prior to assembly. 2. Install the NEW high pressure fuel pipe. 3. Tighten the NEW high pressure fuel pipe fitting to the fuel rail hand tight. Caution: Refer to Fastener Caution in the Preface section.
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4. Tighten the NEW high pressure fuel pipe fitting to the high pressure fuel pump hand tight to 32 N·m (24 lb ft).
5. Install the high pressure fuel pump insulator.
6. Position the high pressure fuel pump cover. 7. Install the high pressure fuel pump cover bolts and tighten to 10 N·m (89 lb in).
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8. Connect the engine wiring harness electrical connector (1) to the high pressure fuel pump. 9. Install the engine wiring harness clip (3) to the high pressure fuel pump cover. 10. Inspect for leaks using the following procedure: 10.1. Turn ON the ignition, with the engine OFF for 2 seconds. 10.2. Turn OFF the ignition, for 10 seconds. 10.3. Turn ON the ignition, with the engine OFF. 10.4. Inspect for fuel leaks. 11. Install the low side fuel pressure service port cap. 12. Tighten the fuel fill cap.
13. Install the air inlet screen support and nuts and tighten to 10 N·m (89 lb in). 14. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101782
Fuel Injection Fuel Rail Assembly Replacement Removal Procedure
1. Disconnect the engine wiring harness electrical connector (1) from the fuel injector wiring harness electrical connector. 2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
3. Remove the fuel injector insulator. © 2010 General Motors Corporation. All rights reserved.
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4. Relieve the high side fuel system pressure. Refer to Fuel Pressure Relief. 5. Disconnect the engine wiring harness electrical connector (1) from the high pressure fuel pump.
6. Remove the high pressure fuel pump cover bolts. 7. Remove the high pressure fuel pump cover. 8. Remove the engine wiring harness clip from the high pressure fuel pump cover.
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9. Remove the high pressure fuel pump insulator.
10. Loosen the high pressure fuel pipe fitting at the fuel pump. 11. Loosen the high pressure fuel pipe fitting at the fuel rail. 12. Remove and discard the high pressure fuel pipe.
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13. Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors. 14. Remove the fuel rail bolts (1). Note: Carefully remove the fuel rail. The fuel injectors may come out of the cylinder head with the fuel rail. 15. Carefully remove the fuel rail (2). 16. If the fuel injectors have been removed with the fuel rail, reinstall the injectors. Refer to Direct Fuel Injector Replacement.
17. Remove and discard the fuel injector upper O-ring seal (1). 18. Inspect the plastic spacer (2) for damage, remove if damaged.
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Note: Applying force to the plastic housing of the sensor will destroy the sensor. To tighten or loosen, only apply force to the attached hexagon. 19. If replacing the fuel rail, remove the fuel injection fuel rail fuel pressure sensor. 20. Remove the fuel injector wiring harness.
Installation Procedure
1. If the fuel rail was replaced, lubricate the threads and sealing cone of the NEW fuel rail with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent. 2. Lubricate the threads and sealing cone of the sensor with silicon free engine oil
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GM P/N 12345610 (Canadian P/N 993193) or equivalent. Caution: Refer to Fastener Caution in the Preface section. Note: Applying force to the plastic housing of the sensor will destroy the sensor. To tighten or loosen, only apply force to the attached hexagon. 3. Install the fuel injection fuel rail fuel pressure sensor and tighten to 33 N·m (25 lb ft). 4. Install the fuel injector wiring harness.
5. Install a NEW plastic spacer (2) if the old one was damaged. 6. Lubricate a NEW fuel injector upper O-ring seal (1) with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent. 7. Install the NEW fuel injector upper O-ring seal (1).
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8. Place the fuel rail (2) into position. 9. Install the 2 outer fuel rail bolts (1) first hand tight, and then install the remaining 2 bolts, hand tight. 10. Connect the fuel injector wiring harness electrical connectors to the fuel injectors.
11. Tighten the fuel rail bolts in the sequence shown. • Tighten the bolts a first pass to 22 N·m (16 lb ft). • Tighten the bolts a final pass to 22 N·m (16 lb ft).
12. Ensure that the high pressure fuel pump, and fuel rail fittings are clean prior to assembly. 13. Lubricate the high pressure fuel pump, and the fuel rail fittings with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent. 14. Install a NEW high pressure fuel pipe. 15. Tighten the NEW high pressure fuel pipe fitting to the fuel rail hand tight.
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16. Tighten the NEW high pressure fuel pipe fitting to the fuel pump hand tight to 32 N·m (24 lb ft).
17. Install the high pressure fuel pump insulator.
18. Install the engine wiring harness clip to the high pressure fuel pump cover. 19. Install the high pressure fuel pump cover. 20. Install the high pressure fuel pump cover bolts and tighten to 10 N·m (89 lb in).
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21. Connect the engine wiring harness electrical connector (1) to the high pressure fuel pump.
22. Install the fuel injector insulator. 23. Install the intake manifold. Refer to Intake Manifold Replacement.
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24. Connect the engine wiring harness electrical connector (1) to the fuel injector wiring harness electrical connector. 25. Inspect for leaks using the following procedure: 25.1. Turn ON the ignition, with the engine OFF for 2 seconds. 25.2. Turn OFF the ignition, for 10 seconds. 25.3. Turn ON the ignition, with the engine OFF. 25.4. Inspect for fuel leaks. 26. Install the low side fuel pressure service port cap. 27. Tighten the fuel fill cap. 28. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
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2009 Pontiac Solstice
Page 1 of 4
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101788
Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement Removal Procedure
1. Relieve the high side fuel system pressure. Refer to Fuel Pressure Relief. 2. Disconnect the fuel injector wiring harness electrical connector (1) from the fuel injection fuel rail fuel pressure sensor.
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Note: Do NOT reposition the foam insulator as damage to the insulator may occur. 3. Insert a 27 mm socket through the opening in the foam insulator (2) onto the fuel injection fuel rail fuel pressure sensor (1).
Note: Applying force to the plastic housing of the sensor will destroy the sensor. To tighten or loosen, only apply force to the attached hexagon. 4. 5. 6. 7.
Place a clean shop towel under the fuel injection fuel rail pressure sensor to fuel rail location. Remove and discard the fuel injection fuel rail fuel pressure sensor (1). Allow any fuel to drain from the fuel rail and pressure sensor location. Dry the sealing cone in the fuel rail and the area around the sensor joint with a lint free cloth. 8. Inspect the sealing cone in the fuel rail. The surface should be free of fuel, debris, and burrs.
Installation Procedure Note: Applying force to the plastic housing of the sensor will destroy the sensor. To tighten or loosen, only apply force to the attached hexagon. Note: Ensure that the fuel rail threads have been cleaned of any excess fuel, or the NEW fuel injection fuel rail fuel pressure sensor will NOT seal properly.
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1. Lubricate the threads and the sealing cone in the fuel rail with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent. 2. Lubricate the threads and sealing cone on the NEW fuel injection fuel rail fuel pressure sensor with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent. 3. Install the NEW fuel injection fuel rail fuel pressure sensor hand tight. 4. Remove the NEW fuel injection fuel rail fuel pressure sensor, re-lubricate following steps 1 and 2 above. Caution: Refer to Fastener Caution in the Preface section. 5. Install the NEW fuel injection fuel rail fuel pressure sensor (1) and tighten to 33 N·m (25 lb ft).
6. Connect the fuel injector wiring harness electrical connector (1) to the fuel injection fuel rail
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7. 8. 9. 10.
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fuel pressure sensor. Install a NEW high pressure fuel line. Refer to Fuel Feed Intermediate Pipe Replacement. Install the low side fuel pressure service port cap. Tighten the fuel fill cap. Inspect for fuel leaks using the following procedure: 10.1. Place a sheet of paper towel in between the bottom of the sensor and the top of the generator. 10.2. Start the vehicle and allow the vehicle to idle for approximately 5 minutes. 10.3. Shut the vehicle off. 10.4. Remove the paper towel and inspect the towel for wetting. If wetting is noted repeat steps 1 through 5.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101789
High Pressure Fuel Pump Replacement Removal Procedure
1. Relieve the low and high side fuel system pressure. Refer to Fuel Pressure Relief. 2. Disconnect the engine wiring harness electrical connector (1) from the high pressure fuel pump. 3. Remove the engine wiring harness clip (3) from the high pressure fuel pump cover.
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4. Remove the high pressure fuel pump cover bolts. 5. Remove the high pressure fuel pump cover.
6. Remove the high pressure fuel pump insulator.
7. Loosen the fuel feed pipe to fuel pump fitting. 8. Remove the fuel feed pipe bolts. 9. Remove the fuel feed pipe from the intake manifold.
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10. Loosen the high pressure fuel pipe fitting at the fuel pump. 11. Loosen the high pressure fuel pipe fitting at the fuel rail. 12. Remove and discard the high pressure fuel pipe.
13. 14. 15. 16.
Remove Remove Remove Remove
and discard the high pressure fuel pump bolts. the high pressure fuel pump. and discard the high pressure fuel pump gasket. and discard the high pressure fuel pump O-ring.
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17. Remove the high pressure fuel pump roller lifter, if necessary.
Installation Procedure
1. Lubricate the high pressure fuel pump cylinder head bore and roller lifter with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent. 2. Install the high pressure fuel pump roller lifter, if necessary.
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3. Install a NEW high pressure fuel pump O-ring. 4. Position the NEW high pressure fuel pump gasket to the cylinder head. Note: Ensure the plastic bolt retainers are installed in the high pressure fuel pump mounting holes prior to installing. 5. Install the high pressure fuel pump. Push the pump into the cylinder head bore by hand, applying force to the top of the pump. 6. Install the NEW high pressure fuel pump bolts hand tight. 7. Ensure that the high pressure fuel pump, and fuel rail fittings are clean prior to assembly. 8. Lubricate the high pressure fuel pump, and the fuel rail fittings with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
9. Install the NEW high pressure fuel pipe.
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10. Tighten the high pressure fuel pipe fitting to the fuel rail hand tight. 11. Tighten the high pressure fuel pipe fitting to the fuel pump hand tight.
12. Place the fuel feed pipe onto the intake manifold. 13. Install the fuel feed pipe bolts hand tight. Caution: Refer to Fastener Caution in the Preface section. 14. Tighten the fuel feed pipe to fuel pump fitting hand tight. 14.1. Tighten the fuel feed pipe bolts to 10 N·m (89 lb in). 14.2. Tighten the fuel feed pipe to fuel pump fitting to 30 N·m (22 lb ft). 14.3. Tighten the high pressure fuel pipe fittings to 32 N·m (24 lb ft). 14.4. Tighten the high pressure fuel pump bolts evenly to 15 N·m (11 lb ft).
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15. Install the high pressure fuel pump insulator.
16. Position the high pressure fuel pump cover. 17. Install the high pressure fuel pump cover bolts and tighten to 10 N·m (89 lb in).
18. Connect the engine wiring harness electrical connector (1) to the high pressure fuel pump. 19. Install the engine wiring harness clip (3) to the fuel pump cover. 20. Inspect for leaks using the following procedure: 20.1. Turn ON the ignition, with the engine OFF for 2 seconds. 20.2. Turn OFF the ignition, for 10 seconds. 20.3. Turn ON the ignition, with the engine OFF.
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20.4. Inspect for fuel leaks. 21. Install the low side fuel pressure service port cap. 22. Tighten the fuel fill cap.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101791
Direct Fuel Injector Replacement Special Tools • EN-47909 Injector Bore and Sleeve Cleaning Kit • EN-48266 Injector Seal Installer and Sizer • J 2619-01 Slide Hammer • J-37281-A Injector Remover
Removal Procedure
1. Disconnect the engine wiring harness electrical connector (1) from the fuel injector wiring harness electrical connector. 2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
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3. Remove the fuel injector insulator.
4. Relieve the high side fuel system pressure. Refer to Fuel Pressure Relief. 5. Disconnect the engine wiring harness electrical connector (1) from the high pressure fuel pump. 6. Remove the engine wiring harness clip (3) from the high pressure fuel pump cover.
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7. Remove the high pressure fuel pump cover bolts. 8. Remove the high pressure fuel pump cover.
9. Remove the high pressure fuel pump insulator.
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10. Loosen the high pressure fuel pipe fitting at the fuel pump. 11. Loosen the high pressure fuel pipe fitting at the fuel rail. 12. Remove and discard the high pressure fuel pipe.
13. Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors. 14. Remove the fuel rail bolts (1). Note: Carefully remove the fuel rail. The fuel injectors may come out of the cylinder head with the fuel rail. 15. Carefully remove the fuel rail (2).
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16. Remove and discard the direct fuel injector hold down clamps.
17. Remove the direct fuel injectors.
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18. If necessary, use the J 2619-01 and the J-37281-A in order to remove the direct fuel injector (s).
19. Remove and discard the upper O-ring seal (1) and plastic spacer (2) from the injector(s). 20. Carefully remove and discard the lower nylon seal (4) from the injector(s).
Installation Procedure
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1. Install a NEW plastic spacer (2) onto the fuel injector(s). 2. Lubricate a NEW O-ring seal (1) with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent. 3. Install the NEW O-ring seal (1) onto the fuel injector(s).
4. From the EN-48266 , position the EN 48266-1 to the injector tip.
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Note: DO NOT lubricate the NEW seal. 5. Install a NEW seal onto the EN 48266-1.
6. Pull the NEW seal by hand over the EN 48266-1 and into the groove in the injector. 7. Remove the EN 48266-1 from the injector tip.
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8. From the EN-48266 , install the EN 48266-2 to the injector tip.
9. Using the EN 48266-2, re-size the seal. Install the EN 48266-2, until it bottoms out against the injector body, and rotate the EN 48266-2 while applying only moderate force 180 degrees in one direction and then 180 degrees back in the other direction. 10. Remove the EN 48266-2.
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11. Install the direct fuel injectors to the cylinder head.
12. Install the NEW direct fuel injector hold down clamps.
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13. Place the fuel rail (2) into position. 14. Install the 2 outer fuel rail bolts (1) first, hand tight and install the remaining 2 bolts, hand tight. 15. Connect the fuel injector wiring harness electrical connectors to the fuel injectors. Caution: Refer to Fastener Caution in the Preface section.
16. Tighten the fuel rail bolts in the sequence shown. • Tighten the bolts a first pass to 22 N·m (16 lb ft). • Tighten the bolts a final pass to 22 N·m (16 lb ft).
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17. Ensure that the high pressure fuel pump, and fuel rail fittings are clean prior to assembly. 18. Lubricate the high pressure fuel pump, and the fuel rail fittings with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent. 19. Install the NEW high pressure fuel pipe. 20. Tighten the NEW high pressure fuel pipe fitting to the fuel rail hand tight. 21. Tighten the NEW high pressure fuel pipe fitting to the fuel pump hand tight to 32 N·m (24 lb ft).
22. Install the high pressure fuel pump insulator.
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23. Install the high pressure fuel pump cover. 24. Install the high pressure fuel pump cover bolts and tighten to 10 N·m (89 lb in).
25. Connect the engine wiring harness electrical connector (1) to the high pressure fuel pump. 26. Install the engine wiring harness clip (3) to the high pressure fuel pump cover.
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27. Install the fuel injector insulator.
28. Connect the engine wiring harness electrical connector (1) to the fuel injector wiring harness electrical connector. 29. Inspect for leaks using the following procedure: 29.1. Turn ON the ignition, with the engine OFF for 2 seconds. 29.2. Turn OFF the ignition, for 10 seconds. 29.3. Turn ON the ignition, with the engine OFF. 29.4. Inspect for fuel leaks. 30. Install the low side fuel pressure service port cap. 31. Tighten the fuel fill cap. 32. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
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Document ID: 2101794
2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101794
Evaporative Emission Hoses/Pipes Replacement Engine/Chassis Removal Procedure
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief. 2. Disconnect the evaporative emission (EVAP) pipe (1) quick connect fitting from the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service. 3. Disconnect the fuel feed pipe (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service. 4. Cap or plug the fuel feed pipe, fuel rail and EVAP line to in order to system prevent contamination.
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5. Remove the fuel feed and evaporative emission (EVAP) pipe clip from the oil level indicator tube bracket.
6. Ensure that the area around the brake pipe connections is free of dirt and/or debris. 7. Remove the brake pipes from the brake pressure modulator valve (BPMV), if equipped.
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8. Remove the brake pipes from the proportioning valve, if equipped. 9. Cap or plug the BMPV or the proportioning valve in order to prevent system contamination. 10. Remove the fuel tank. Refer to Fuel Tank Replacement.
11. Remove the brake hose clips (2) from both the right and left brake hose brackets. 12. Remove the right and left brake pipes (1) from the brake hoses. (left side shown, right side similar).
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13. Remove the pipe clips (1) from the following: • Rear suspension lower control arm bracket • Left hand brace floor panel tunnel
14. Remove the pipe clips (1) from the following: • Floor panel number 4 cross bar • Rear carrier bracket • Right hand brace floor panel tunnel 15. Remove the pipe clip (2) from the floor panel rear reinforcement. 16. Have an assistant support the fuel feed, EVAP, and brake pipe assembly.
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17. 18. 19. 20. 21.
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Remove the pipe clip (1) from the underbody side rail. Remove the pipe clip (2) from the floor panel tunnel brace stud. Remove the pipe clip (3) from the floor panel tunnel brace stud. Remove the pipe clips (4) from the floor panel studs. Remove the fuel feed, EVAP, and brake pipe assembly from the vehicle and place on a suitable work surface.
22. Disconnect the EVAP canister purge line (6) from the EVAP line. Refer to Plastic Collar Quick Connect Fitting Service. 23. Remove the retaining clip (1) from the lines. 24. Open the clips (4 and 7), and remove the EVAP line (3) from the clips. 25. Inspect and replace and damaged clips.
Installation Procedure
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1. Install the EVAP line (3) to the clips and close the clips (4 and 7). 2. Install the retaining clip (1) to the lines. 3. Connect the EVAP canister purge line (6) to the EVAP line. Refer to Plastic Collar Quick Connect Fitting Service.
4. With the aid of an assistant, install the fuel feed, EVAP, and brake pipe assembly to the vehicle. 5. Install the pipe clips (4) to the floor panel studs. 6. Install the pipe clip (3) to the floor panel tunnel brace stud. 7. Install the pipe clip (2) to the floor panel tunnel brace stud. 8. Install the pipe clip (1) to the underbody side rail.
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9. Install the pipe clip (2) to the floor panel rear reinforcement. 10. Install the pipe clips (1) from the following: • Floor panel number 4 cross bar • Rear carrier bracket • Right hand brace floor panel tunnel
11. Install the pipe clips (1) to the following: • Rear suspension lower control arm bracket • Left hand brace floor panel tunnel
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12. Install the right and left brake pipes (1) to the brake hoses. (left side shown, right side similar). 13. Install the brake hose clips (2) to both the right and left brake hose brackets.
14. Install the fuel tank. Refer to Fuel Tank Replacement. 15. Remove the cap or plug from the BMPV or the proportioning valve. Caution: Refer to Fastener Caution in the Preface section. 16. Install the brake pipes to the proportioning valve, if equipped, and tighten to 20 N·m (15 lb ft).
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17. Install the brake pipes to the BPMV, if equipped, and tighten to 20 N·m (15 lb ft).
18. Install the fuel feed and EVAP pipe clip to the oil level indicator tube bracket.
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19. Remove the cap or plug from the fuel feed pipe, fuel rail and EVAP line. 20. Connect the fuel feed pipe (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service. 21. Connect the EVAP pipe (1) to the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service. 22. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. 23. Inspect for fuel leaks using the following procedure: 23.1. Turn ON the ignition, with the engine OFF for 2 seconds. 23.2. Turn OFF the ignition for 10 seconds. 23.3. Turn ON the ignition, with the engine OFF. 23.4. Inspect for fuel leaks.
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Document ID: 1829291
2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 1829291
Evaporative Emission Hoses/Pipes Replacement Canister/Fuel Tank Removal Procedure
1. Remove the fuel tank. Refer to Fuel Tank Replacement. 2. Disconnect the evaporative emission (EVAP) line quick connect fitting from the fuel pump module. Refer to Plastic Collar Quick Connect Fitting Service. 3. Disconnect the EVAP line quick connect fitting at the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service. 4. Disconnect the EVAP line from the roll over valve. Refer to Plastic Collar Quick Connect Fitting Service. 5. Cap or plug the EVAP connections, fuel pump module, and canister in order to prevent system contamination. 6. Disengage the EVAP line from the fuel tank retaining features. 7. Remove the EVAP line (1) from the fuel tank.
Installation Procedure
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1. 2. 3. 4.
Install the EVAP line (1) to the fuel tank. Engage the EVAP vapor line to the fuel tank retaining features. Remove the caps or plugs from the EVAP line connections, fuel pump module, and canister. Connect the EVAP line quick connect fitting to the roll over valve. Refer to Plastic Collar Quick Connect Fitting Service. 5. Connect the EVAP line quick connect fitting at the fuel sender. Refer to Plastic Collar Quick Connect Fitting Service. 6. Connect the EVAP line quick connect fitting at the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service. 7. Install the fuel tank. Refer to Fuel Tank Replacement.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 1829292
Evaporative Emission Hoses/Pipes Replacement Chassis/Canister Removal Procedure
1. Remove the fuel tank. Refer to Fuel Tank Replacement. 2. Disconnect the evaporative emission (EVAP) canister purge line quick connect fitting (1) at the chassis line. Refer to Plastic Collar Quick Connect Fitting Service. 3. Remove the EVAP canister purge line.
Installation Procedure
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1. Install the EVAP canister purge line. 2. Connect the EVAP canister purge line quick connect fitting (1) to the chassis. Refer to Plastic Collar Quick Connect Fitting Service. 3. Install the fuel tank. Refer to Fuel Tank Replacement.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 1829293
Fuel Tank Filler Evaporative Emission Pipe Replacement Removal Procedure
1. Remove the fuel fill pipe. Refer to Fuel Tank Filler Pipe Replacement. 2. Disconnect the fuel tank fill evaporative emission (EVAP) pipe quick connect fitting (1) at the fuel pump module. Refer to Plastic Collar Quick Connect Fitting Service. 3. Remove the fuel tank fill EVAP pipe.
Installation Procedure
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1. Install the fuel tank fill EVAP pipe. 2. Connect the fuel tank fill EVAP pipe quick connect fitting (1) to the fuel pump module. Refer to Plastic Collar Quick Connect Fitting Service. 3. Install the fuel fill pipe. Refer to Fuel Tank Filler Pipe Replacement.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101812
Evaporative Emission Canister Purge Solenoid Valve Replacement Removal Procedure
1. Disconnect the chassis evaporative emission (EVAP) line quick connect fitting (2) from the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service.
2. Disconnect the engine wiring harness electrical connector (1) from the EVAP canister purge © 2010 General Motors Corporation. All rights reserved.
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solenoid.
3. 4. 5. 6.
Remove the EVAP canister purge solenoid bolt (6). Remove the EVAP canister purge solenoid (5). Remove the EVAP canister purge solenoid O-ring seal (4), if necessary. Inspect for carbon release in the EVAP canister purge solenoid ports. If there is any loose carbon, replace the EVAP canister and any components necessary to remove the carbon particles.
Installation Procedure
1. Install the EVAP canister purge solenoid O-ring seal (4) to the solenoid, if necessary. 2. Lubricate the O-ring seal with clean engine oil.
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3. Install the EVAP canister purge solenoid to the intake manifold. Caution: Refer to Fastener Caution in the Preface section. 4. Install the EVAP canister purge solenoid bolt and tighten to 10 N·m (89 lb in).
5. Connect the engine wiring harness electrical connector (1) to the EVAP canister purge solenoid.
6. Connect the chassis EVAP line quick connect fitting (2) to the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 1829296
Evaporative Emission Canister Vent Solenoid Valve Replacement Removal Procedure
1. Remove the fuel tank. Refer to Fuel Tank Replacement. 2. Disconnect the evaporative emission (EVAP) canister vent solenoid valve tube quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service. 3. Depress the locking tab on the EVAP canister vent solenoid valve mount and slide the valve out of the canister.
Installation Procedure
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1. Install the EVAP canister vent solenoid valve onto the mount on the canister, push the valve forward until the locking tab engages. 2. Connect the EVAP canister vent tube quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service. 3. Install the fuel tank. Refer to Fuel Tank Replacement.
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Document ID: 1829297
2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 1829297
Evaporative Emission Canister Replacement Removal Procedure
1. Remove the fuel tank. Refer to Fuel Tank Replacement. 2. Remove the evaporative emission (EVAP) canister/fuel tank line. Refer to Evaporative Emission Hoses/Pipes Replacement - Canister/Fuel Tank. 3. Slide the EVAP canister upward from the bracket.
Installation Procedure
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1. Slide the NEW EVAP canister down into the bracket. 2. Install the EVAP canister/fuel tank line. Refer to Evaporative Emission Hoses/Pipes Replacement - Canister/Fuel Tank. 3. Install the fuel tank. Refer to Fuel Tank Replacement.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101819
Evaporative Emission System Cleaning Special Tools J 41413 EVAP Pressure and Purge Station
Inspection Procedure Caution: Use the EVAP Pressure/Purge Diagnostic Station J 41413 in order to provide a clean, dry, low pressure gas source. Do not substitute any other pressurized gas source. Damage may result to the EVAP system. Note: Proceed with the following procedure only if referenced by an evaporative emission (EVAP) diagnostic or repair procedure. 1. Turn OFF the ignition. 2. Remove the EVAP canister purge solenoid. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement. 3. Lightly tap the EVAP canister purge valve on a hard surface. 4. Inspect for carbon particles exiting either of the vacuum ports. • If no carbon particles were detected, but a blockage was detected during a diagnostic procedure, install the original EVAP canister purge valve. Continue with the cleaning procedure. • If carbon particles are found during the inspection procedure, continue with the cleaning procedure. • If a diagnostic procedure directed you to replace the EVAP canister purge valve and no carbon particles were detected, replace the EVAP canister purge valve. Return to the published service procedure.
Cleaning Procedure 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Raise the vehicle. Refer to Lifting and Jacking the Vehicle. Remove the EVAP canister. Refer to Evaporative Emission Canister Replacement. Turn OFF the main valve on the J 41413 . Disconnect the hose from the diagnostic station pressure regulator. Using a section of vacuum hose, connect one end onto the EVAP pressure/purge diagnostic station pressure regulator. Connect the other end of the vacuum hose to the canister side of the purge pipe. Turn ON the main nitrogen cylinder valve and continue to discharge nitrogen for 15 seconds. If the nitrogen does not clear the blockage, replace the purge pipe. Return the EVAP pressure/purge diagnostic station to the stations original condition. Install a new EVAP canister. Refer to Evaporative Emission Canister Replacement. Lower the vehicle. Install a new EVAP canister purge solenoid. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement. Return to the diagnostic table that sent you here.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101823
Ignition Coil Replacement Removal Procedure
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement. 2. Disconnect the ignition coil electrical connector(s).
3. Remove the ignition coil bolt(s). 4. Remove the ignition coil(s). © 2010 General Motors Corporation. All rights reserved.
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Installation Procedure Caution: Refer to Fastener Caution in the Preface section.
1. Install the ignition coil(s). 2. Install the ignition coil bolt(s) and tighten to 10 N·m (89 lb in).
3. Connect the ignition coil electrical connector(s). 4. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 1829349
Spark Plug Inspection Spark Plug Usage •
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Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug.
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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 •
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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. •
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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:
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- 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. •
Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4).
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•
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Inspect for evidence of improper arcing.
- Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. 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. •
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.
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Spark Plug Visual Inspection •
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Normal operation--Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives.
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Carbon Fouled--Dry, fluffy black carbon, or soot caused by the following conditions:
- Rich fuel mixtures • Leaking fuel injectors
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• 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.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101836
Spark Plug Replacement Removal Procedure Caution: This engine has aluminum cylinder heads. Do not remove the spark plugs from a hot engine, allow it to cool first. Removing the spark plugs from a hot engine may cause spark plug thread damage or cylinder head damage.
1. Remove the ignition coil(s). Refer to Ignition Coil Replacement. Note: Make sure that any water and/or debris is blown out of the spark plug holes prior to removing the spark plugs. 2. Remove the spark plugs using a 5/8 inch spark plug socket.
Installation Procedure Caution: Refer to Fastener Caution in the Preface section.
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Caution: Do not coat spark plug threads with anti-seize compound. If anti-seize compound is used and spark plugs are over-torqued, damage to the cylinder head threads may result. 1. Install the spark plugs and tighten to 20 N·m (15 lb ft). Specification The spark plug gap is 0.90 mm (0.035 in). 2. Apply dielectric compound to the spark plug boots and make sure no corrosion is present. 3. Install the ignition coil(s). Refer to Ignition Coil Replacement.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101838
Crankshaft Position Sensor Replacement Removal Procedure
1. Remove the starter. Refer to Starter Motor Replacement. 2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor.
3. Remove the CKP sensor bolt. 4. Remove the CKP sensor.
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Installation Procedure
1. Lubricate the CKP sensor O-ring seal with clean engine oil. Caution: Refer to Fastener Caution in the Preface section. 2. Install the CKP sensor. 3. Install the CKP sensor bolt and tighten to 10 N·m (89 lb in).
4. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 5. Install the starter. Refer to Starter Motor Replacement.
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101842
Camshaft Position Sensor Replacement - Intake Removal Procedure
1. Remove the fuel feed intermediate pipe. Refer to Fuel Feed Intermediate Pipe Replacement. 2. Disconnect the engine wiring harness electrical connector (2) from the intake camshaft position (CMP) sensor.
3. Remove the CMP sensor bolt. 4. Remove the CMP sensor.
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Installation Procedure
Note: Inspect the CMP sensor for damage, replace as necessary. 1. Lubricate the CMP sensor O-ring seal with clean engine oil. Caution: Refer to Fastener Caution in the Preface section. 2. Install the CMP sensor. 3. Install the CMP sensor bolt and tighten to 10 N·m (89 lb in).
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4. Connect the engine wiring harness electrical connector (2) to the intake CMP sensor. 5. Install the fuel feed intermediate pipe. Refer to Fuel Feed Intermediate Pipe Replacement.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101865
Camshaft Position Sensor Replacement - Exhaust Removal Procedure
1. Disconnect the engine wiring harness electrical connector (4) from the exhaust camshaft position (CMP) sensor.
2. Remove the CMP sensor bolt. (Intake CMP shown, exhaust CMP similar) 3. Remove the CMP sensor. © 2010 General Motors Corporation. All rights reserved.
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Installation Procedure
Note: Inspect the CMP sensor for damage. Replace as necessary. 1. Lubricate the CMP sensor O-ring seal with clean engine oil. Caution: Refer to Fastener Caution in the Preface section. 2. Install the CMP sensor. (Intake CMP shown, exhaust CMP similar) 3. Install the CMP sensor bolt and tighten to 10 N·m (89 lb in).
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4. Connect the engine wiring harness electrical connector (4) to the exhaust CMP sensor.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101867
Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement. 2. Disconnect the engine wiring harness electrical connector from either the intake (2) or exhaust (1) camshaft position actuator solenoid valve, as required.
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3. Remove the exhaust (1) camshaft position actuator solenoid valve bolt and valve, as required. 4. Remove the intake (2) camshaft position (CMP) actuator solenoid valve bolt and valve, as required. 5. Inspect the solenoid valve O-ring seals from damage, replace as necessary.
Installation Procedure Caution: Refer to Fastener Caution in the Preface section.
1. Lubricate the solenoid valve O-ring seals with clean engine oil. 2. Install the intake (2) CMP actuator solenoid valve and bolt, as required, and tighten to 10 N·m (89 lb in). 3. Install the exhaust (1) CMP actuator solenoid valve and bolt, as required, and tighten to 10 N·m (89 lb in).
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4. Connect the engine wiring harness electrical connector to the intake (1) or exhaust (2) camshaft position actuator solenoid valve, as required. 5. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101871
Knock Sensor Replacement Removal Procedure
1. Disconnect the engine wiring harness electrical connector (2) from the front knock sensor, if required.
2. Disconnect the engine wiring harness electrical connector (2) from the rear knock sensor, if required. © 2010 General Motors Corporation. All rights reserved.
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3. Remove the front knock sensor clip (1) from the oil level indicator tube, if required. 4. Remove the rear knock sensor clip (2) from the intake manifold brace, if required.
5. Loosen the appropriate knock bolt. 6. Remove the appropriate knock sensor.
Installation Procedure Note: Rotate the pigtail 90 degrees from vertical before securing the fastener.
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1. Position the appropriate knock sensor to the engine block. Caution: Refer to Fastener Caution in the Preface section. 2. Tighten the appropriate knock bolt to 25 N·m (18 lb ft).
3. Install the front knock sensor clip (1) to the oil level indicator tube, if required. 4. Install the rear knock sensor clip (2) to the intake manifold brace, if required.
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5. Connect the engine wiring harness electrical connector (2) to the rear knock sensor.
6. Connect the engine wiring harness electrical connector (2) to the front knock sensor.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101873
Intake Air Pressure and Temperature Sensor Replacement Removal Procedure
1. Disconnect the engine wiring harness electrical connector (2) from the intake air pressure and temperature sensor.
2. Remove the intake air pressure and temperature sensor bolts. © 2010 General Motors Corporation. All rights reserved.
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3. Remove the intake air pressure and temperature sensor.
Installation Procedure
1. Lubricate the intake air pressure and temperature sensor O-ring with clean engine oil. 2. Install the intake air pressure and temperature sensor. Caution: Refer to Fastener Caution in the Preface section. 3. Install the intake air pressure and temperature sensor bolts and tighten to 9 N·m (80 lb in).
4. Connect the engine wiring harness electrical connector (2) to the intake air pressure and
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temperature sensor.
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101876
Charge Air Bypass Valve Solenoid Replacement Removal Procedure
1. Disconnect the engine wiring harness electrical connector from the charge air bypass solenoid. 2. Reposition the charge air bypass solenoid vacuum hose clamp (5) at the turbocharger and remove the hose. 3. Remove the charge air bypass solenoid vacuum hose from the turbocharger coolant feed hose clamps (4). 4. Reposition the charge air bypass solenoid vacuum hose clamp (3) at the charge air cooler outlet pipe and remove the hose. 5. Reposition the charge air bypass solenoid vacuum hose clamp (1) at the intake manifold and remove the hose. 6. Remove the charge air bypass solenoid bolts (2).
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7. Remove the charge air bypass solenoid.
Installation Procedure
1. Position the charge air bypass solenoid to the engine. Caution: Refer to Fastener Caution in the Preface section.
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2. Install the charge air bypass solenoid bolts (2) and tighten to 10 N·m (89 lb in). 3. Install the charge air bypass solenoid vacuum hose to the intake manifold and position the clamp (1). 4. Install the charge air bypass solenoid vacuum hose to the charge air cooler outlet pipe and position the clamp (3). 5. Install the charge air bypass solenoid vacuum hose to the turbocharger coolant feed hose clamps (4). 6. Install the charge air bypass solenoid vacuum to from the turbocharger and install the clamp (5). 7. Connect the engine wiring harness electrical connector to the charge air bypass solenoid.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101877
Charge Air Bypass Valve Replacement
Callout
Component Name
Preliminary Procedure Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement. Charge Air Bypass Bolt Caution: Refer to Fastener Caution in the Preface section. 1
Procedure Disconnect the vacuum hose. Tighten 10 N·m (89 lb in)
2
Charge Air Bypass Valve
3
Charge Air Bypass Valve Diaphragm Spring
4
Charge Air Bypass Valve Diaphragm
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2161524
Turbocharger Wastegate Actuator Replacement
Callout
Component Name
Preliminary Procedure Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement. Wastegate Actuator Bolt Caution: Refer to Fastener Caution in the Preface section. 1
Procedure Disconnect the vacuum hose. Tighten 10 N·m (89 lb in)
2
Turbocharger Wastegate Actuator
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101882
Air Cleaner Element Replacement Removal Procedure
1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF) sensor.
2. Loosen the air cleaner outlet duct clamp (1) at the air cleaner housing. 3. Remove the air cleaner outlet duct from the air cleaner housing. © 2010 General Motors Corporation. All rights reserved.
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4. 5. 6. 7.
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Unlatch the upper air cleaner cover retainer clips. Remove the upper air cleaner cover. Remove the air cleaner filter from the lower air cleaner housing. Inspect the air cleaner filter for dust, dirt, and water contamination. Replace as necessary. Refer to Maintenance Schedule.
Installation Procedure
1. Install the NEW air cleaner filter into the lower air cleaner housing. 2. Install the upper air cleaner cover to the lower air cleaner housing. 3. Latch the upper air cleaner cover retainer clips.
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4. Install the air cleaner outlet duct to the air cleaner housing. Caution: Refer to Fastener Caution in the Preface section. 5. Tighten the air cleaner outlet duct clamp (1) at the air cleaner housing to 4 N·m (35 lb in).
6. Connect the engine wiring harness electrical connector (1) to the MAF sensor.
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101885
Air Cleaner Assembly Replacement Removal Procedure
1. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement. 2. Remove the charge air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement. 3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement. 4. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF) sensor.
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5. Remove the air cleaner assembly front bolt. 6. Firmly tug on the air cleaner lower assembly in order to disengage the air cleaner from the studs. 7. Remove the air cleaner assembly from the vehicle.
Installation Procedure
1. Install the air cleaner assembly to the vehicle. 2. Position the air cleaner assembly over the studs. Firmly press down over the studs in order to engage the air cleaner to the studs. Caution: Refer to Fastener Caution in the Preface section. 3. Install the air cleaner assembly front bolt and tighten to 10 N·m (89 lb in).
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4. 5. 6. 7.
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Connect the engine wiring harness electrical connector (1) to the MAF sensor. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement. Install the charge air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement. Install the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement.
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Document ID: 2101889
2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101889
Air Cleaner Outlet Duct Replacement Removal Procedure
1. 2. 3. 4.
Disconnect the positive crankcase ventilation (PCV) tube from the air cleaner outlet duct. Loosen the air cleaner outlet duct clamp (1) at the air cleaner housing. Loosen the air cleaner outlet duct clamp (2) at the turbocharger. Remove the air cleaner outlet duct.
Installation Procedure
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1. Install the air cleaner outlet duct. 2. Tighten the air cleaner outlet duct clamp (2) at the turbocharger. Caution: Refer to Fastener Caution in the Preface section. 3. Tighten the air cleaner outlet duct clamp (1) at the air cleaner housing to 4 N·m (35 lb in). 4. Connect the PCV tube to the air cleaner outlet duct.
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2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101891
Charge Air Cooler Inlet Pipe Replacement Removal Procedure
1. Remove the hood. Refer to Hood Replacement. 2. Remove the horn. Refer to Horn Replacement. 3. Remove the charge air cooler inlet pipe bolt (3) at the rear bracket.
4. Remove the charge air cooler rear bracket nut (2) and bracket (1). © 2010 General Motors Corporation. All rights reserved.
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5. Remove the charge air cooler inlet pipe bolt (1) at the front bracket. 6. Loosen the charge air cooler clamp (2) at the charge air cooler inlet pipe. 7. Loosen the charge air cooler inlet pipe clamp (4) at the charge air cooler pipe.
8. Remove the charge air cooler inlet pipe. 9. Remove any oil film from inside the pipes.
Installation Procedure
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1. Install the charge air cooler inlet pipe to the charge air cooler pipe and the charge air cooler. Caution: Refer to Exterior Trim Emblem Removal Caution in the Preface section.
2. Install the charge air cooler rear bracket (1) and nut (2). Tighten the nut to 9 N·m (80 lb in).
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3. Install the charge air cooler inlet pipe bolt (3) at the rear bracket and tighten to 7 N·m (62 lb in). 4. Install the charge air cooler inlet pipe bolt (1) at the front bracket and tighten to 7 N·m (62 lb in). 5. Tighten the charge air cooler clamp (2) at the charge air cooler pipe. 6. Tighten the charge air cooler inlet pipe clamp (4) at the charge air cooler pipe to 5 N·m (44 lb in). 7. Install the horn. Refer to Horn Replacement. 8. Install the hood. Refer to Hood Replacement.
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Document ID: 2157394
2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2157394
Charge Air Cooler Coolant Hose Replacement Removal Procedure
1. Loosen the charge air cooler hose clamp (1) at the throttle body. 2. Loosen the charge air cooler hose clamp (2) at the charge air cooler outlet pipe. 3. Remove the charge air cooler hose from the throttle body and the outlet pipe.
Installation Procedure
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1. Install the charge air cooler hose to the outlet pipe and the throttle body. 2. Tighten the charge air cooler hose clamp (2) at the charge air cooler outlet pipe. Caution: Refer to Fastener Caution in the Preface section. 3. Tighten the charge air cooler hose clamp (1) at the throttle body. Tighten Tighten the charge air cooler hose clamps to 5 N·m (44 lb in).
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Document ID: 2101897
2009 Pontiac Solstice
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| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101897
Charge Air Cooler Outlet Pipe Replacement Removal Procedure
1. Disconnect the engine wiring harness electrical connector (2) from the intake air pressure and temperature sensor.
2. Reposition the charge air bypass valve solenoid vacuum hose clamp (3) at the charge air cooler outlet pipe. © 2010 General Motors Corporation. All rights reserved.
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3. Remove the vacuum hose from the charge air cooler outlet pipe.
4. Remove the charge air cooler outlet pipe bolt (1) at the rear bracket.
5. Remove the charge air cooler rear bracket nut (4) and bracket (1).
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6. Loosen the charge air cooler hose clamp (2) at the throttle body charge air cooler outlet hose. 7. Remove the charge air cooler outlet pipe from the throttle body charge air cooler hose (1). 8. If needed, remove the throttle body charge air cooler hose (1) from the throttle body.
9. 10. 11. 12.
Remove the charge air cooler outlet pipe bolt (3) at the front bracket. Loosen the charge air cooler clamp (2) at the charge air cooler outlet pipe. Remove the charge air cooler outlet pipe. Remove any oil film from inside the pipes and hoses.
Installation Procedure
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1. Install the charge air cooler outlet pipe to the charge air cooler and the charge air cooler hose. Caution: Refer to Fastener Caution in the Preface section. 2. Install the charge air cooler outlet pipe bolt (3) at the front bracket and tighten to 7 N·m (62 lb in).
3. Install the charge air cooler rear bracket (1) and nut (4). Tighten the nut to 9 N·m (80 lb in).
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4. Install the charge air cooler outlet pipe bolt (1) at the rear bracket and tighten to 7 N·m (62 lb in). 5. Tighten the charge air cooler clamp (2) at the charge air cooler outlet pipe and tighten to 5 N·m (44 lb in).
6. If removed, install the throttle body charge air cooler hose (1) onto the throttle body and tighten to 5 N·m (44 lb in). 7. Install the charge air cooler outlet pipe to the throttle body charge air cooler hose. 8. Tighten the throttle body charge air cooler hose clamp (2) at the charge air cooler outlet pipe to 5 N·m (44 lb in).
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9. Install the vacuum hose to the charge air cooler outlet pipe. 10. Position the charge air bypass valve solenoid vacuum hose clamp (3) at the charge air cooler outlet pipe.
11. Connect the engine wiring harness electrical connector (2) to the intake air pressure and temperature sensor.
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Document ID: 2101900
2009 Pontiac Solstice
Page 1 of 2
| SKY, Solstice (VIN M) Service Manual | Engine | Engine Controls and Fuel - 2.0L | Repair Instructions | Document ID: 2101900
Charge Air Cooler Replacement Removal Procedure
1. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement. 2. Remove the charge air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement. 3. Remove the front radiator air deflector. Refer to Radiator Air Lower Baffle and Deflector Replacement. 4. Remove the front bumper fascia air deflector. Refer to Front Bumper Fascia Air Deflector Replacement. 5. Remove the charge air cooler bolts. 6. Remove the charge air cooler.
Installation Procedure
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1. Install the charge air cooler. Caution: Refer to Fastener Caution in the Preface section. 2. Install the charge air cooler bolts and tighten to 9 N·m (80 lb in). 3. Install the front bumper fascia air deflector. Refer to Front Bumper Fascia Air Deflector Replacement. 4. Install the front radiator air deflector. Refer to Radiator Air Lower Baffle and Deflector Replacement. 5. Install the charge air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement. 6. Install the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement.
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