Engine Performance

1992 Chevrolet Corvette
1991-92 ENGINE PERFORMANCE 1991-92 Saturn, 1992 All Other Models - Removal, Overhaul & Installation
1991-92 ENGINE PERFORMANCE
1991-92 Saturn, 1992 All Other Models - Removal, Overhaul & Installation
INTRODUCTION
WARNING: When battery is disconnected, vehicle computer and memory systems

may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle. See COMPUTER RELEARN
PROCEDURES article in the GENERAL INFORMATION Section before
disconnecting battery.
Removal, overhaul and installation procedures (when given by manufacturer) are covered in this article. If
component removal and installation is primarily an unbolt and bolt-on procedure, only a simple TORQUE
specification may be supplied.
IGNITION SYSTEM
ELECTRONIC CONTROL MODULE (ECM)
CAUTION: Electronic components used in control systems are designed to carry

very low voltages. As little as a 30-volt charge created by static
electricity can cause a total or degrading failure in ECM or other
electronic components containing integrated circuits. Before servicing
ECM, ground yourself and ground the work area to discharge stored
electricity.
STATIC CHARGE (VOLTS)

Relative Humidity 10- Relative Humidity
Movement 20% 65-90%
Handling Clear Plastic Bag 20,000 1200
Handling Vinyl Envelope 7000 600
Sliding On Velour Seat 15,000 400
Walking On Carpet 35,000 1500
Walking On Tile/Vinyl 12,000 50
CAUTION: DO NOT remove part from packaging until ready to install. Ground any
static-proof package before opening. DO NOT touch electrical terminals
of components unless properly grounded. DO NOT lay electrical
components on car seat, carpeting or dashboard. Use electrostatic
protection mat and ground strap whenever possible. See Fig. 1.
Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

lunes, 27 de febrero de 2017 12:37:02
12:35:47 p. m. Page 1 © 2011 Mitchell Repair Information Company, LLC.
Fig. 1: Servicing ECM Using 3M Anti-Static Mat

Courtesy of GENERAL MOTORS CORP.
NOTE: Before replacing ECM, carefully inspect all wiring and control components.
Failure to test for short circuits may result in repeated ECM failure due to
grounds and Quad-Driver failure. To prevent internal damage to ECM, ensure
ignition switch is in OFF position when disconnecting or reconnecting ECM
connectors or 12-volt components.
Removal
Ensure ignition switch is in OFF position. Disconnect negative battery cable. Remove electrical connectors
from ECM. Remove ECM from vehicle. Remove MEM-CAL or PROM and CAL-PAK (if equipped) from
ECM.
Installation
Install PROM and CAL-PAK (if equipped) or MEM-CAL in new ECM. Install ECM into vehicle. Connect
electrical connectors to ECM. Install access panels. Reconnect negative battery cable to battery.
CAL-PAK
Removal & Installation
Some ECM models use a CAL-PAK as well as a PROM. See Fig. 2. If replacing ECM, remove CAL-PAK
from old ECM and install in new ECM. Removal and replacement procedures for CAL-PAK are same as for
PROM. See PROGRAMMABLE READ-ONLY MEMORY (PROM) under IGNITION SYSTEM. If
units are improperly installed, grounding diagnostic test lead will set Code 52.

lunes, 27 de febrero de 2017 12:35:47 p. m. Page 2 © 2011 Mitchell Repair Information Company, LLC.
Fig. 2: Locating PROM & CAL-PAK on ECM

MEM-CAL
Removal
Disconnect negative battery cable. Remove ECM from vehicle. Using 2 fingers, push retaining clips back
from MEM-CAL; at the same time, grasp MEM-CAL at both ends and lift out of socket. DO NOT remove
MEM-CAL cover.
Installation
1. Carefully align MEM-CAL pins with ECM pin holes. DO NOT press in middle of MEM-CAL. Push
downward evenly on ends of MEM-CAL until retaining clips on ends of MEM-CAL snap into place.
2. Install ECM. Reconnect negative battery cable. Turn ignition on and ground ALDL connector. Code
12 should flash at least 4 times (if no other codes are present). If Code(s) 42, 43, 51 or 52 is present,
or if CHECK ENGINE light stays on constantly with code(s) present, MEM-CAL is not fully seated
or is defective. If it is necessary to remove MEM-CAL, follow previous removal instructions.
PROGRAMMABLE READ-ONLY MEMORY (PROM)
Removal
1. Remove ECM from vehicle. See ELECTRONIC CONTROL MODULE under IGNITION
SYSTEM. Position ECM so bottom cover faces upward. Remove slide-off PROM access cover by
depressing locking tab.
2. Using PROM removal tool, grasp PROM at narrow ends. Gently rock PROM from end to end while
pulling up. If installing new PROM, remove old PROM from PROM carrier. See Fig. 2.
NOTE: Note reference notch locations in PROM, carrier and ECM for reassembly
reference.
Installation
1. Ensure new PROM has same service number as old one. Place new PROM in PROM carrier. Position
PROM carrier squarely over ECM PROM socket. Press on PROM carrier until PROM is firmly seated
in ECM.
NOTE: Ensure reference notches in both ECM and PROM are properly aligned.
If PROM is installed backwards, PROM will be destroyed when ignition
is turned on.
2. Install PROM access cover on ECM. Install ECM in vehicle. See ELECTRONIC CONTROL
MODULE (ECM) under IGNITION SYSTEM. Start engine and ground ALDL diagnostic test
connector. Watch for trouble Code 51 or 52.
3. If Code 51 or 52 occurs, PROM is either not fully seated in ECM or installed backwards, has bent
pins or is defective. If bent pins crack when trying to straighten, replace PROM. If PROM is installed
backwards or is defective, replace PROM.
ELECTRONIC SPARK CONTROL (ESC) MODULE
NOTE: ESC module is mounted to firewall on a bracket behind the distributor.
Turn ignition off. Remove bracket-to-firewall screws. Rotate bracket to access ESC module. Disconnect
ESC module harness connector. Remove ESC mounting screws and remove ESC module. To install, reverse
removal procedure.
IGNITION MODULE (DIS)
NOTE: If spark plug boots adhere to spark plugs, use Boot Remover (J-36011).
Twist first and then pull upward. Boots must be in place on housing before
installing ignition system assembly, or damage may result.
Removal & Installation (1.9L, 2.0L, 2.2L, 2.5L, 3.1L & 3.4L)
1. Disconnect negative battery cable. Unplug connectors at ignition module. See Fig. 3-5. Disconnect
spark plug wires from coil pack. Remove ignition module from engine block. For ignition module
location, see COMPONENT LOCATIONS in I - SYS/COMP TESTS article. Also, remove coils and
assembly plate (if possible).
2. On 2.5L engines, inspect crankshaft sensor "O" ring (on base of ignition module) for wear, cracks or
other damage. Replace as necessary. Lubricate new "O" ring with engine oil before installing.
3. To install, reverse removal procedure. Tighten ignition coil nuts and module to specification. See
TORQUE SPECIFICATIONS table at end of article.

Fig. 3: Locating Distributorless Ignition Module Components, 2.5L (1.9L & 2.2L Similar)
Fig. 4: Locating Distributorless Ignition Module Components, 3.1L & 3.4L


Fig. 5: Locating Distributorless Ignition Module Components, 2.0L

IGNITION MODULE (IDI)
Removal & Installation (2.3L)
1. Disconnect negative battery cable. Disconnect 11-pin harness connector. Remove 4 ignition module
cover-to-cam carrier bolts.
2. Remove ignition system assembly from engine. Remove 4 housing cover screws. Remove housing
cover. Remove coil harness connector from module. Remove module-to-cover screws. Remove
module from cover. To install, reverse removal procedure.
NOTE: DO NOT wipe grease from module or coil if module is not being replaced. If
installing a new module, spread silicone grease on metal face of module and
on cover where module seats. Grease is included with new module and is
necessary for module cooling purposes.
IGNITION MODULE C3I

Removal & Installation (3.3L & 3.8L)
Disconnect negative battery cable. Unplug 14-way connector at ignition module. Disconnect spark plug
wires from coil pack. Remove nuts and washers securing ignition module to bracket. Remove coil-to-
ignition module Torx screws. Note wire colors for reassembly. Unplug connectors between ignition coil and
module. Remove module. To install, reverse removal procedure.
CRANKSHAFT/COMBINATION SENSOR C3I
Removal (3.3L & 3.8L)
1. Remove serpentine belt from crankshaft pulley. Raise vehicle on hoist. Remove right front tire and
wheel assembly. Remove right inner fender access cover.
2. Using 28-mm socket, remove crankshaft harmonic balancer retaining bolt. Remove harmonic
balancer. Remove foreign object deflector (DO NOT use pry bar). Disconnect sensor harness
connector. Remove sensor and pedestal (as an assembly) from block. Remove sensor from pedestal.
Installation
1. Loosely install sensor on pedestal. Position sensor with pedestal attached onto Installer (J-37089). See
Fig. 6. Position installer onto crankshaft.
Fig. 6: Installing Crankshaft/Combination Sensor C3I

2. Install pedestal-to-block bolts. Tighten bolts to 18-26 ft. lbs. (25-35 N.m). Tighten pedestal pinch bolt
to 26-44 INCH lbs. (3-5 N.m). Remove installer. Install foreign object deflector. Place harmonic
balancer onto installer. Rotate balancer on installer. If any vanes of interrupter rings contact installer,
replace harmonic balancer.
3. Install balancer on crankshaft. To complete installation, reverse removal procedure. Tighten balancer
retaining bolt to specification. See TORQUE SPECIFICATIONS table at end of article.
CAMSHAFT SENSOR C3I
Removal & Installation (3.3L & 3.8L)
Disconnect negative battery cable. Remove camshaft sensor attaching bolt. Disconnect wiring harness and
remove sensor. To install, reverse removal procedure.
CRANKSHAFT POSITION SENSOR (DIS & IDI)
Removal & Installation (1.9L, 2.0L, 2.2L, 2.3L, 3.1L & 3.4L)
Disconnect sensor harness connector. Remove bolt and sensor from engine block. Inspect crankshaft sensor
"O" ring for wear, cracks or other damage. Replace as necessary. Lubricate new "O" rings with engine oil
before installing. To install, reverse removal procedure.
Remove DIS ignition module. Remove crankshaft sensor mounting screws, and remove sensor from DIS
module. Inspect "O" ring for wear before installing DIS module. Replace as necessary. To install, reverse
removal procedure. Tighten screws to specification. See TORQUE SPECIFICATIONS table at end of
article.
IGNITION COIL C3I
Disconnect negative battery cable. Remove spark plug wires from coil. Remove coil-to-module bolts.
Remove coil assembly. To install, reverse removal procedure. Tighten retaining bolts to specification. See
Disconnect negative battery cable. Remove spark plug wires from coil pack. Remove coil-to-ignition
module Torx screws. Tilt coil assembly back. Disconnect module connectors and remove coil pack. To
install, reverse removal procedure. Tighten retaining bolts to specification. See TORQUE
SPECIFICATIONS table at end of article.
IGNITION COILS (DIS) - 1.9L, 2.0L, 2.2L, 2.5L, 3.1L - VIN T & 3.4L
Disconnect negative battery cable. Remove spark plug wires from coils. Remove nuts or screws from
ignition coils. Remove coils. To install, reverse removal procedure.
IGNITION COILS (IDI) - 2.3L

1. Disconnect negative battery cable. Disconnect 11-pin harness connector. Remove ignition cover-to-
cam carrier bolts. Remove ignition system assembly from engine. Remove housing cover screws.
Remove housing cover.
2. Remove coil harness connector from module. Remove module-to-cover screws. Remove module from
cover. To install, reverse removal procedures. Tighten screws to specification. See TORQUE
HEI DISTRIBUTOR (3.1L - VIN D, 4.3L, 4.6L, 4.9L, 5.0L, 5.7L - VINS K, 7 AND 8, AND 7.4L)
Removal
1. Make sure ignition switch is in the "OFF" position.

2. Remove air cleaner (if necessary).
3. Remove electrical connector(s) from distributor,
4. Loosen distirbutor cap bolts/screws. Set aside distributor cap, If plug wires need to be removed, mark
wires for installation reference.
5. Note installed position of distributor rotor in relation to engine. Note installed position of distributor
housing in relation to engine. Marking rotor installed position, and distributor housing installed
position, will help with installation reference.
6. Remove distributor hold down bolt/screw. Remove hold down clamp (if eauipped).
7. Note rotation of distributor rotor as distributor assembly is pulled upward and mark rotor position
when it stops rotation.
8. Remove distributor from vehicle.
9. Remove distributor gasket from distributor assembly.
Installation
1. Install NEW gasket to distributor assembly.

2. Place distributor in position, with housing pointing toward position first noted during removal, and
with rotor pointing to position where it stopped rotating upon removal.
3. Lower distributor into engine. Distributor rotor should rotate to its original position first noted during
removal. Install distributor Hold down clamp and bolt/screw. Tighten bolt/screw to 27 ft. lb. (36
N.m).
4. Reinstall distributor cap.
5. If plug wires were removed, reinstall pllug wires as identified during removal.
6. Install distributor electrical connector(s).
7. reinstall air cleaner (if removed).
8. Check ignition timing. See IGNITION TIMING in appropriate ADJUSTMENTS article.
OPTI-SPARK DISTRIBUTOR (5.7L VIN P)
1. Disconnect negative battery cable. Drain cooling system. Disconnect Intake Air Temperature (IAT)
sensor harness connector. Remove knock sensor. Remove air intake duct. Remove serpentine belt.
Remove coolant hoses to water pump assembly.

2. Disconnect coolant temperature sensor harness connector. Remove water pump-to-engine block
mounting bolts (6). Remove water pump assembly. See Fig. 7. Remove crankshaft harmonic balancer.
See Fig. 8. Remove belt tensioner. Remove spark plug wires from distributor. See Fig. 9.
3. Disconnect 4-terminal ECM connector to distributor. Remove distributor mounting bolts (3). Pull
distributor forward until distributor shaft disengages from engine. Mark top surface of distributor shaft
for reassembly purposes. Remove coil as necessary. See Fig. 10.
4. To install, ensure mark made on distributor shaft during removal is on top or facing up. To complete
installation, reverse removal procedure. Refill coolant and check for leaks. Tighten distributor hold-
down bolts to 96 INCH lbs. (11 N.m).
Fig. 7: Removing & Installing Water Pump & Related Components

Courtesy of GENERAL MOTORS CORP

Fig. 8: Removing & Installing Crankshaft Harmonic Balancer


Fig. 9: Identifying Distributor Wiring Locations


Fig. 10: Removing & Installing Coil & Related Components

FUEL SYSTEM
FUEL PRESSURE RELIEF (PFI)
WARNING: ALWAYS relieve fuel pressure before disconnecting any fuel injection-
related component. DO NOT allow fuel to contact engine or electrical
components.
1. Fuel system is under pressure. Relieve pressure before servicing fuel system. Fuel pressure may be
relieved using one of 2 different methods.
2. One method is to disconnect fuel pump connector. Start engine and allow to run until it stops. Operate
starter for 3 seconds to remove remaining fuel from fuel lines. Reconnect fuel pump once repair is
complete.
3. The other method is to install Fuel Pressure Gauge (J-34730-1 or SA9127E for Saturn) on fuel
pressure test port. When installing fuel pressure gauge, wrap shop towel around pressure connection
to absorb fuel leakage. Place gauge bleed hose in container. Open bleed valve to bleed fuel pressure.
FUEL PRESSURE RELIEF (TBI)
WARNING: Always relieve fuel pressure before disconnecting any fuel injection-
related component. DO NOT allow fuel to contact engine or electrical
components.
Disconnect negative battery cable. Remove fuel filler cap. Since these TBI units contain an internal bleed-
down feature, system fuel pressure should dissipate after a short time.
THROTTLE BODY (PFI)

Removal
1. Relieve fuel pressure. See FUEL PRESSURE RELIEF (PFI) under FUEL SYSTEM. Remove air
inlet ducts. Disconnect and mark electrical connections and vacuum hoses from throttle body.
Disconnect control cables from throttle body.
2. Drain cooling system. Remove coolant hoses. Remove throttle body retaining bolts. Remove throttle
body and gasket.
NOTE: Identification number is stamped on throttle body. Use identification number

to order replacement components.
Installation
1. To install, reverse removal procedure using new gasket. Tighten retaining bolts to specification. See
TORQUE SPECIFICATIONS table at end of article. Refill cooling system.
2. If installing new Idle Air Control (IAC), ensure IAC pintle length setting is adjusted before
installation. See IDLE AIR CONTROL (IAC) VALVE. Adjust idle speed and TPS (if removed and
if adjustable). See appropriate ADJUSTMENTS article in this section.
THROTTLE BODY (TBI)
NOTE: Ensure residual fuel pressure is relieved before working on throttle body.
Removal (Throttle Body - All Models)
1. Relieve fuel pressure. See FUEL PRESSURE RELIEF (TBI). Disconnect negative battery cable.
Remove air cleaner and related ducting.
2. Remove electrical connectors from Idle Air Control (IAC), TPS and fuel injector(s). Lay wiring
harness aside. Remove throttle cable, return springs, transmission/transaxle cable, and cruise control
cable (if equipped). Label and remove vacuum hoses.
3. Remove fuel feed and return lines. Use back-up wrenches to prevent nuts in throttle body from
coming loose. Remove fuel line "O" rings and discard. Remove throttle body retaining bolts. Remove
TBI unit and base gasket. Discard base gasket.
WARNING: Pressure regulator spring is under heavy tension and can cause injury
if released. DO NOT immerse cover in any type of cleaning solvent.
Disassembly (Fuel Meter Assembly - Model 700)
Remove fuel meter-to-throttle body retaining screws. Remove fuel meter assembly. See Fig. 11. Discard
gasket. If fuel pressure regulator cover is removed, replace regulator diaphragm to prevent fuel leaks.
Remove TPS and IAC assembly. Throttle valve screws are staked in position and should not be removed.

Fig. 11: Exploded View of Throttle Body Assembly (Model 700)

Cleaning & Inspection
1. Clean all metal parts in a cold immersion-type cleaner such as Carbon X (X-55). Blow dry using
compressed air.
2. DO NOT immerse the following in cleaner solvent: TPS, IAC, throttle body cover, fuel meter and
pressure regulator assemblies, fuel injector, fuel filter, rubber parts and diaphragms.
3. Inspect mating surfaces for damage that may prevent gasket sealing. Repair or replace components as
necessary.
Reassembly
1. Install new fuel meter-to-throttle body assembly gasket. Match cutout portions of gasket with
openings in throttle body assembly.
2. Place fuel meter assembly on throttle body. Install fuel meter-to-throttle body retaining screws and
washers (screws should be coated with locking compound). Tighten screws to specification. See
3. Install new "O" rings on fuel lines. Using a back-up wrench on fuel fittings, tighten fuel line nuts to 20
ft. lbs. (27 N.m). To complete reassembly, reverse disassembly procedure.
Disassembly (Throttle Body Cover - Model 220)
1. Place throttle body on Holding Fixture (J-9789-118 or BT 30-15) to prevent damage to throttle valve.
Remove cover-to-throttle body screws, noting location of 2 short screws.
2. Remove throttle body cover. See Fig. 12. Throttle body cover and pressure regulator are serviced as
an assembly. DO NOT remove pressure regulator-to-cover screws. Remove TPS and IAC assembly.
Throttle valve screws are staked in position and should not be removed.

Fig. 12: Exploded View of Throttle Body Assembly (Model 220)

1. Clean all metal parts in a cold immersion-type cleaner such as Carbon X (X-55). Blow dry using
compressed air.
necessary.
Reassembly
1. Install new dust seal into recess of throttle body. Install fuel outlet passage gasket on cover. Install
throttle body cover gasket on throttle body. Install cover; ensure pressure regulator dust seal and cover
gaskets are in place.

2. Apply thread locking compound to cover attaching screws. Install cover screws and lock washers.
Tighten screws. Connect electrical lead to fuel injector and install air cleaner. To complete assembly,
reverse disassembly procedure.
Disassembly (Fuel Meter Assembly - Saturn)
Remove fuel meter-to-throttle body retaining screws. Remove fuel meter assembly. See Fig. 13. Discard
gasket. If fuel pressure regulator cover is removed, replace regulator diaphragm to prevent fuel leaks.
Remove TPS and IAC assembly. Throttle valve screws are staked in position and should not be removed.

Fig. 13: Exploded View of Throttle Body Assembly (Saturn)

1. Clean all metal parts in a cold immersion-type cleaner such as Carbon X (X-55). Blow dry with
compressed air.
necessary.
Reassembly
1. Install new fuel meter-to-throttle body assembly gasket. Match cutout portions of gasket with
openings in throttle body assembly.
2. Place fuel meter assembly on throttle body. Install fuel meter-to-throttle body retaining screws and
washers (screws should be coated with locking compound). Tighten screws to specification. See
3. Install new "O" rings on fuel lines. Using a back-up wrench on fuel fittings, tighten fuel line nuts. To
complete reassembly, reverse disassembly procedure.
Installation (Throttle Body - All Models)
1. Install throttle body unit to intake manifold using new gaskets. Tighten retaining bolts to specification.
See TORQUE SPECIFICATIONS table at end of article. Install new "O" rings onto fuel lines.
2. Connect fuel feed and return lines throttle body. Use a back-up wrench to prevent fuel line fittings in
throttle body from turning. Tighten fuel line nuts to specifications. See TORQUE
FUEL PRESSURE REGULATOR
NOTE: On TBI models, fuel pressure regulator is integral with fuel meter assembly.
See THROTTLE BODY (TBI).
Removal (1.9L, 2.0L, 2.3L, 3.3L, 3.8L & 4.9L)
1. Relieve fuel pressure. See FUEL PRESSURE RELIEF (PFI). Disconnect pressure regulator-to-fuel
rail hose. On 2.3L, remove fuel rail. See FUEL RAIL & INJECTORS (PFI).
2. On all models, remove pressure regulator retaining bolts. Remove pressure regulator from fuel rail.
On 2.3L, remove pressure regulator retainer and seal from fuel rail.
Installation
To install, reverse removal procedure. Always replace "O" rings. Lubricate fuel rail seal with oil and install
in regulator. Tighten bolts to specification. See TORQUE SPECIFICATIONS table at end of article.

1. Relieve fuel pressure. See FUEL PRESSURE RELIEF (PFI). Remove upper manifold or intake
manifold plenum. On 3.1L models, remove fuel rails. See FUEL RAIL & INJECTORS (PFI).
2. On all models, remove inlet and return fuel fittings and gaskets. Remove pressure regulator-to-bracket
retaining bolts. Separate pressure regulator from fuel rail.
3. Remove pressure regulator base-to-fuel rail connector tubes from pressure regulator.
Installation
1. To install, reverse removal procedure. Lubricate new "O" rings with oil. Install fuel return "O" rings
on fuel rails. Return "O" rings are larger in diameter than connector tube "O" rings.
2. Tighten bolts to specification. See TORQUE SPECIFICATIONS table at end of article.
1. Relieve fuel pressure, and remove fuel rails. Refer to FUEL PRESSURE RELIEF (PFI) and FUEL
RAIL & INJECTORS (PFI).
2. Remove front crossover tube retainer on right fuel rail. Remove rear crossover tube retainer at
pressure regulator on right fuel rail. Separate fuel rail assemblies.
3. Remove pressure regulator bracket-to-fuel rail bolt. Remove bracket-to-regulator base bolt. Remove
bracket. Remove fuel outlet tube-to-right fuel rail bolt. Remove base-to-right fuel rail bolt.
4. Remove pressure regulator assembly from fuel rail. Rotate pressure regulator and remove from outlet
tube. Remove base-to-fuel rail connector tube. Remove "O" rings from connector tube, outlet tube and
crossover tubes.
Installation
To install, reverse removal procedures. Install new "O" rings and lubricate with oil. Tighten retaining bolts
to specification. See TORQUE SPECIFICATIONS table at end of article.
FUEL RAIL & INJECTORS (PFI)
CAUTION: DO NOT remove fuel inlet fitting on 2.3L or 3.3L engines. Inlet fitting is
staked to fuel rail.
Removal (1.9L, 2.0L, 3.3L & 3.8L)
1. Relieve fuel pressure. See FUEL PRESSURE RELIEF (PFI). Turn ignition off. Disconnect wiring
connectors from injectors. Disconnect and plug hoses to fuel rail.
2. Remove fuel rail retaining bolts. Remove injector-to-fuel rail retaining clip (if used). Separate fuel rail
from injectors. Remove injectors. See Fig. 14 through Fig. 16.

Fig. 14: Locating Fuel Rail Assembly Components (1.9L)


Fig. 15: Locating Fuel Rail Assembly Components (2.0L, 3.3L & 3.8L)

Fig. 16: Locating Fuel Rail Assembly Components (4.9)

NOTE: If injector is replaced, ensure replacement injector has the same part number
as that removed.
Installation
To install, reverse removal procedure. Coat new "O" rings with engine oil. Install "O" rings on injectors.
Tighten fuel rail retaining bolts to specification. See TORQUE SPECIFICATIONS table at end of article.
Removal (2.3L)
1. Relieve fuel pressure. See FUEL PRESSURE RELIEF (PFI). Remove crankcase ventilation
oil/vapor separator.
2. Remove fuel lines from fuel rail. Remove vacuum line at pressure regulator. Disconnect wiring
connector while pushing inward on connector. Remove fuel rail retaining bolts. Remove fuel rail. See
Fig. 17.
3. Remove injector-to-fuel rail retaining clip. Remove injector from fuel rail. Remove injector "O" rings.

Fig. 17: Locating Fuel Rail Assembly Components (2.3L)

Installation
To install reverse removal procedure. Lubricate injector "O" rings with engine oil. Install injector-to-fuel rail
retaining clip, with open end facing injector electrical connection. Tighten fuel rail retaining bolts.
Removal (3.1L, 3.4L, 5.0L & 5.7L)
1. Relieve fuel pressure. See FUEL PRESSURE RELIEF (PFI). Disconnect negative battery cable.
Remove intake manifold upper plenum. Disconnect and mark vacuum lines. Remove EGR-to-intake
manifold retaining bolts. Some models use an EGR pipe which requires removal at EGR base.
2. Remove throttle cable bracket bolts. Disconnect cables and electrical wiring connections from throttle
body. Remove throttle body from intake manifold. Remove plenum and gasket. See Fig. 18.

Fig. 18: Locating Fuel Rail Assembly Components (3.1L, 5.0L & 5.7L)
3. Disconnect vacuum hose to pressure regulator. Remove runners. Disconnect fuel lines from fuel rail.
With ignition off, disconnect electrical connections from injectors.
4. Remove fuel rail retaining bolts. Remove fuel rail and injectors. On 5.0L and 5.7L, rotate injector
retaining clip to unlock. On all models, remove injectors from fuel rail. Remove "O" rings from
injectors.
Installation
To install, reverse removal procedure. Coat new "O" rings with oil. Install "O" rings on injectors. Tighten
bolts to specification. See TORQUE SPECIFICATIONS table at end of article.
Removal (4.9L)
1. Remove air cleaner. Relieve fuel pressure. See FUEL PRESSURE RELIEF (PFI). Disconnect
negative battery cable. Remove power steering pump and set aside.
2. Disconnect vacuum hose to pressure regulator and base assembly. Disconnect accelerator cable, cruise
control cable and bracket. Disconnect electrical connectors. Drain coolant and disconnect coolant hose
to thermostat housing.
3. Wrap shop towel around fuel line, and disconnect fuel feed line from rear fuel rail assembly and fuel
return line. Discard "O" rings. Disconnect EGR vacuum hose. Remove EGR valve. Remove fuel rail
attaching bolts. Disconnect electrical connectors at front and rear fuel rail assemblies. Remove fuel
rail from intake manifold. See Fig. 14 & 11.
Installation
To install, reverse removal procedure. Coat new "O" rings with engine oil. Install "O" rings on injectors.
Tighten bolts to specification. See TORQUE SPECIFICATIONS table at end of article.
THROTTLE BODY FUEL INJECTOR (TBI)
Removal (Model 220)

1. Relieve fuel pressure. See FUEL PRESSURE RELIEF (TBI). Remove throttle body cover, leaving
cover gasket in place. Using screwdriver and fulcrum, carefully pry injector out. See Fig. 19. Remove
small "O" ring from nozzle end of injector.
2. Carefully rotate injector fuel filter back and forth to remove fuel filter from base of injector. Remove
and discard throttle body cover gasket. Remove large "O" ring and steel back-up washer from top
counterbore of throttle body injector cavity.
Fig. 19: Removing Throttle Body Injector (Typical)

Installation
1. Install fuel filter on nozzle end of fuel injector. Ensure large end of filter faces injector so filter covers
the raised rib at base of injector. Lubricate small "O" ring with engine oil, and push "O" ring on
nozzle end of injector until it presses against injector filter.
2. Install steel back-up washer in top counterbore of throttle body injector cavity. Lubricate large "O"
ring with ATF, and install "O" ring directly over back-up washer. See Fig. 12. Ensure "O" ring is
seated properly in cavity and is flush with top of throttle body casting.
CAUTION: Back-up washer and large "O" ring must be installed before
injector. Improper seating of "O" ring will cause fuel leak.
3. Install "O" ring on injector. Install injector into cavity by aligning raised lug on injector base with
cast-in notch of throttle body cavity. Push down on injector until fully seated. Electrical terminals of
injector will be approximately parallel with throttle shaft. Install throttle body cover.
Removal (Model 700)
Relieve fuel pressure. See FUEL PRESSURE RELIEF (TBI) under FUEL SYSTEM. Remove fuel
injector retainer screw and remove retainer. Using screwdriver and fulcrum on side of injector opposite
connector terminals, carefully pry injector out. See Fig. 19. Remove upper and lower "O" rings and discard.
Installation
1. Lubricate new upper and lower "O" rings with engine oil, and place them on injector. Ensure upper
ring is in groove and lower ring is flush against filter.
2. Position injector in fuel meter assembly, with electrical connector facing cutout for wire grommet.
3. Push injector down to seat in cavity. Install injector retainer. Coat injector retainer screw with thread
locking compound and install. Tighten screw to 27 INCH lbs. (3.0 N.m).
Removal (Saturn)
Relieve fuel pressure. See FUEL PRESSURE RELIEF (TBI). Remove fuel injector retainer screw and
remove retainer. Using screwdriver and fulcrum on side of injector opposite connector terminals, carefully
pry injector out. See Fig. 19. Remove upper and lower "O" rings and discard.
Installation
1. Lubricate new upper and lower "O" rings with engine oil, and place them on injector. Ensure upper
ring is in groove and lower ring is flush against filter.
2. Position injector in fuel meter assembly, with electrical connector facing cutout for wire grommet.
Push injector down to seat in cavity. Install injector retainer. Coat injector retainer screw with thread
locking compound and install. Tighten retainer screw to 35 INCH lbs. (4.0 N.m).
IDLE SPEED CONTROL MOTOR (4.9L VIN B)
Remove air cleaner. Disconnect electrical connector. Remove retaining screws and Idle Speed Control (ISC)
motor. To install, reverse removal procedure. To adjust ISC minimum and maximum authority, see
ADJUSTMENTS article in this section.
NOTE: The ISC motor is factory calibrated and should not be disassembled.
Replace motor as a complete assembly only. DO NOT soak ISC motor in
carburetor cleaner.
IDLE AIR CONTROL (IAC) VALVE
CAUTION: For calibration purposes, several different style IAC valves are used.
Ensure replacement valve has the same part number as original valve.
Removal

On TBI models, remove air cleaner and related ducting. On all models, remove electrical connector from
IAC valve. Remove IAC valve, gasket and "O" ring from throttle body assembly.
CAUTION: DO NOT extend or retract pintle if IAC valve has been in service, or
damage to worm gear will result.
Installation
1. Inspect gasket or "O" ring for damage. Replace as necessary. Check the extended distance of IAC
pintle before installing. Damage will occur if measurement is incorrect. Distance must not exceed 1
1/8" (28 mm). Measurement should be taken from valve housing flange to end of pintle cone.
2. To retract new IAC valve pintle, slowly exert finger pressure on valve. Install new "O" ring or gasket
on valve. Coat "O" ring with engine oil. Install IAC valve. Tighten IAC valve to specification. See
TORQUE SPECIFICATIONS table at end of article. Install electrical connector.
3. To reset IAC valve, refer to ADJUSTMENTS article in this section.
FUEL PUMP
Removal (Camaro & Firebird)
1. Relieve fuel system pressure. See FUEL PRESSURE RELIEF (PFI) or FUEL PRESSURE
RELIEF (TBI). Disconnect battery negative terminal. Raise car on hoist. Drain fuel from fuel tank.
Disconnect exhaust pipe at converter and rear hanger. Allow exhaust to hang over axle assembly.
2. Remove tailpipe and muffler heat shields. Remove fuel filler neck shield behind left rear tire. Remove
rear suspension track bar and brace. Disconnect harness connector to fuel pump assembly.
3. Disconnect all fuel lines. Remove fuel line retaining bracket on left side and remove brake line clip
from bracket.
4. Position support jack under axle assembly. Disconnect lower ends of shock absorbers. Disconnect rear
stabilizer bar from frame (if equipped).
5. On models equipped with 2-piece driveshaft, remove center support bearing-to-rear axle torque arm
bolts. On all models, remove rear axle torque arm-to-differential housing bolts/nuts. Wire end of rear
axle torque arm aside. Remove driveshaft-to-differential yoke bolts/screws. Wire end of driveshaft
aside.
6. Lower rear suspension as far as possible without damaging brake lines and cables and remove both
coil springs. Remove tank straps bolts. Remove fuel tank by rotating front of tank down and sliding to
the right. Remove fuel pump assembly from fuel tank.
Removal (Corvette)
1. Relieve fuel system pressure. See FUEL PRESSURE RELIEF (PFI). Remove fuse marked "Fuel
Pump" from fuse block in passenger compartment. Crank engine. Engine will start and run until fuel
in line is exhausted. When engine stops, engage starter again for 3 seconds to ensure engine will not
start.
2. Remove battery ground cable. Remove fuel cap, fuel tank filler door. Remove filler neck housing and
disconnect drain hose. Remove screws attaching fuel meter and pump assembly to tank. Disconnect
fuel hoses, vapor hose and electrical connector from fuel meter and pump assembly. Pull pump up
into pulsator while pulling outward away from bottom support. Remove pump.

Removal (Except Camaro, Corvette & Firebird)
1. Disconnect negative battery cable. Relieve fuel pressure. See FUEL PRESSURE RELIEF (PFI) or
FUEL PRESSURE RELIEF (TBI). Remove filler neck. Lower fuel tank. Disconnect fuel lines and
electrical connection.
2. Remove fuel level sending unit and fuel pump retaining bolts or cam lock ring. Lift assembly from
fuel tank and remove fuel pump from sending unit.
3. Pull fuel pump upward while pulling away from bottom support. Use care not to damage rubber
insulator and strainer.
Installation
To install, reverse removal procedure using NEW "O" ring and gasket. Tighten fasteners to specification.
See TORQUE SPECIFICATIONS.
THROTTLE POSITION SENSOR (TPS)
Removal
Disconnect electrical connection from TPS. Remove TPS retaining screws. Remove TPS.
Installation
1. With throttle valve in closed position, install TPS on throttle body. Ensure TPS lever engages with
drive lever on throttle shaft. Install retaining screws and electrical connection.
2. The TPS on most models are self-zeroing and are not adjustable. On these models, if voltage is less
than 1.25 volts, TPS does not need to be serviced. On models with adjustable TPS, adjust TPS to
specification and tighten retaining screws. See ADJUSTMENTS article.
OXYGEN (O2) SENSOR
O2 sensor is mounted in the exhaust pipe, below exhaust manifold. It is equipped with a permanent pigtail
which must be protected when removing sensor.
Removal
1. Ensure sensor is free of contaminants; avoid using cleaning solvents of any type. Sensor may be
difficult to remove when engine temperature is less than 120°F (48°C). Excessive removal force may
damage threads in exhaust manifold or pipe.
2. Disconnect negative battery cable at battery. Disconnect electrical connector from oxygen sensor.
Carefully remove oxygen sensor from exhaust pipe.
CAUTION: Correct torque of O2 sensor is critical to prevent crushing glass beads

in graphite anti-seize compound. Crushing glass beads will cause
sensor to seize in exhaust manifold. This may necessitate replacement
of exhaust manifold at the next removal.
Installation
1. Whenever an oxygen sensor is removed, threads must be coated with anti-seize compound before it is
reinstalled. New oxygen sensors already have this compound applied to threads.
2. Install oxygen sensor in exhaust pipe, and tighten sensor to 30 ft. lbs. (41 N.m). Reconnect electrical
connector to oxygen sensor. Reconnect negative battery cable.
SUPERCHARGER
NOTE: Servicing of supercharger unit is limited to replacement only.
Removal (3.8L VIN 1)
1. Relieve fuel pressure. See FUEL PRESSURE RELIEF (PFI). Disconnect negative battery cable.
Remove accessory drive belt from supercharger pulley.
2. Remove fuel injector shield. Disconnect fuel supply lines. Disconnect vacuum hoses and all electrical
connectors. Remove fuel rail mounting bolts. Remove fuel rail and injectors as an assembly.
3. Remove air intake duct and EGR pipe from supercharger. Disconnect throttle and cruise control
cables. Remove cable bracket and tensioner bracket to supercharger mounting stud.
NOTE: Tensioner bracket-to-supercharger stud must be removed or

supercharger cannot be lifted high enough to clear lower intake
manifold locator pins.
4. Remove supercharger-to-intake manifold bolts, supercharger gasket and coolant passage "O" rings.
Installation
Ensure locator pins are in their proper location on intake manifold. Replace gaskets and "O" rings. DO NOT
use any type of sealant on gasket. To complete installation, reverse removal procedure. Tighten
supercharger-to-intake manifold bolts to 19 ft. lbs. (26 N.m). Tighten fuel rail mounting bolts to 15 ft. lbs.
(20 N.m).
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Catalytic Converter Hanger Bolts/Screws (Camaro & Firebird) 37 (50)
Center Support Bearing-To-Rear Axle Torque Arm Bolts (Camaro &
Firebird With 2-Piece Driveshaft) 37 (50)
Driveshaft-To-Differential Yoke Bolt/Screw (Camaro & Firebird) 16 (22)
Fuel Tank Strap Bolts (Camaro & Firebird) 25 (34)
Harmonic Balancer C3I
3.3L & 3.8L 200-239 (270-325)
Ignition System
DIS Module-To-Block Bolt
2.2L, 2.5L, 3.1L & 3.4L 15-22 (20-30)
IDI Cover Assembly Bolt (4) 19 (26)
Muffler Hanger Retaining Bolts/Nuts (Camaro & Firebird) 89 (10)
PFI System
Fuel Inlet & Return Line Nuts

2.0L 20 (27)
2.3L, 3.3L, 3.4L & 4.9L 22 (30)
3.1L 17 (23)
5.0L & 5.7L 20 (27)
Fuel Rail Bolt
2.0L & 3.3L 15-20 (20-27)
2.3L 19 (26)
3.8L (VIN 1) 15 (20)
4.9L 18 (24)
5.0L & 5.7L 15 (20)
Fuel Inlet Fitting (1)
3.1L 35 (47)
IAC Valve
2.0L, 5.0L & 5.7L 13 (18)
Intake Runner Bolts
5.0L & 5.7L 19 (26)
Oxygen Sensor 30 (41)
Plenum Bolts
3.1L 16 (22)
5.0L & 5.7L 19 (26)
Throttle Body Bolt
2.0L 10-15 (14-20)
2.3L, 3.1L, 5.0L & 5.7L 19 (26)
3.8L 11 (15)
4.9L 14 (19)
Throttle Body Nut
3.3L 21 (28)
Rear Axle Torque Arm Outer Transmission Bracket (Camaro & Firebird)
Bolt
Front Lower 37 (50)
Rear Upper 20 (27)
Nut 30 (41)
Rear Axle Torque Arm-To-Differential Housing Bolts/Nuts (Camaro & 97 (132)
Firebird)
Rear Axle Track Bar Brace-To-Body Bracket Bolts (Camaro & Firebird)
Left 35 (47)
Right 80 (108)
Rear Axle Track Bar-To-Left Coil Spring Seat Bolt/Nut (Camaro & 61 (83)
Firebird)
Rear Axle Track Bar-To-Right Body Bracket Bolt/Nut (Camaro & Firebird) 80 (108)
Rear Exhaust Pipe Hanger Nut (Camaro & Firebird) 16 (22)
Rear Exhaust Pipe-To-Catalytic Converter Outlet Flange Bolts/Screws 15 (20)
(Camaro & Firebird)

Rear Stabilizer Shaft Insulator Clamp Nuts (Camaro & Firebird) 18 (24)
Rear Stabilizer Shaft Link Bolts/Nuts (Camaro & Firebird) 17 (23)
Shock Absorber Lower Mounting Nut (Camaro & Firebird) 70 (95)
TBI System
Fuel Inlet Fitting 30 (41)
Fuel Outlet Fitting
Model 220 22 (30)
Model 700 30 (41)
Fuel Line Nut 20 (27)
Idle Air Control Valve (Model 220) 13 (18)
Throttle Body-To-Manifold Bolt 18 (24)
Supercharger-To-Manifold Bolt 19 (26)
Wheel Lug Nuts (Camaro & Firebird) 81 (110)
INCH Lbs. (N.m)
Ignition System
Coil-To-Cover Screws
2.3L 35 (4.0)
Crankshaft/Combination Sensor-To-Block Bolt
2.2L 53-106 (6-12)
2.3L 89 (10)
3.1L 71 (8.0)
Crankshaft Sensor-To-Module Screws
2.5L 20 (2.3)
Ignition Coil-To-Module Screws
2.2L, 2.5L & 3.1L 41 (4.6)
Module-To-Cover Screws (3)
2.3L 35 (4.0)
(Model 700 & Saturn) 27 (3.0)
PFI System
Coolant Cover Screws
2.3L 9 (1.0)
3.1L 27 (3.0)
Crossover Tube Retainer Bolt
5.0L & 5.7L 44 (4.9)
Fuel Rail Bolt
3.1L 89 (10)
Fuel Return Line Clamp Bolt
2.3L 53 (6.0)
IAC Valve Housing
3.3L & 3.8L 27 (3.0)
IAC Valve Retaining Screw
1.9L, 2.3L, 3.1L, 3.3L & 3.8L 18 (2.0)
Pressure Regulator Base-To-Rail Bolt
5.0L & 5.7L 44 (4.9)
Pressure
Afinacion de Regulator To Bracket Bolts
Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69
5.0L & 5.7L 44 (4.9)

TBI System
Fuel Injector Screw (Model 700) 27 (3.0)
Fuel Meter Assembly Screw
Model 700 31 (3.5)
Saturn 30 (3.3)
Idle Air Control Valve Retaining Screw (Model 700) 27 (3.0)
Lower Throttle Body-To-Upper Throttle Body Screw (Model 220) 35 (4.0)
Throttle Body Cover Screw (Model 220) 27 (3.0)
Throttle Position Sensor Screw 18 (2.0)
(1) On 2.3L and 3.3L, fuel rail inlet fitting must not be removed from fuel rail. Fitting is staked in
place.


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1992 Chevrolet Corvette

1991-92 ENGINE PERFORMANCE

WARNING: When battery is disconnected, vehicle computer and memory systems

CAUTION: Electronic components used in control systems are designed to carry

STATIC CHARGE (VOLTS)

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Fig. 1: Servicing ECM Using 3M Anti-Static Mat

Removal & Installation

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Fig. 2: Locating PROM & CAL-PAK on ECM

PROGRAMMABLE READ-ONLY MEMORY (PROM)

ELECTRONIC SPARK CONTROL (ESC) MODULE

NOTE: ESC module is mounted to firewall on a bracket behind the distributor.

Removal & Installation

IGNITION MODULE (DIS)

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Fig. 4: Locating Distributorless Ignition Module Components, 3.1L & 3.4L

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Fig. 5: Locating Distributorless Ignition Module Components, 2.0L

IGNITION MODULE (IDI)

Removal & Installation (2.3L)

IGNITION MODULE C3I

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Removal & Installation (3.3L & 3.8L)

CRANKSHAFT/COMBINATION SENSOR C3I

Removal (3.3L & 3.8L)

Fig. 6: Installing Crankshaft/Combination Sensor C3I

CAMSHAFT SENSOR C3I

Removal & Installation (3.3L & 3.8L)

CRANKSHAFT POSITION SENSOR (DIS & IDI)

Removal & Installation (2.5L)

IGNITION COIL C3I

Removal & Installation (3.3L)

Removal & Installation (3.8L)

Removal & Installation

IGNITION COILS (IDI) - 2.3L

Removal & Installation

1. Make sure ignition switch is in the "OFF" position.

1. Install NEW gasket to distributor assembly.

OPTI-SPARK DISTRIBUTOR (5.7L VIN P)

Removal & Installation

Remove coolant hoses to water pump assembly.

Fig. 7: Removing & Installing Water Pump & Related Components

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Fig. 8: Removing & Installing Crankshaft Harmonic Balancer

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Fig. 9: Identifying Distributor Wiring Locations

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Fig. 10: Removing & Installing Coil & Related Components

FUEL PRESSURE RELIEF (TBI)

THROTTLE BODY (PFI)

NOTE: Identification number is stamped on throttle body. Use identification number

THROTTLE BODY (TBI)

Removal (Throttle Body - All Models)

Disassembly (Fuel Meter Assembly - Model 700)

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Fig. 11: Exploded View of Throttle Body Assembly (Model 700)

Cleaning & Inspection

Disassembly (Throttle Body Cover - Model 220)