GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2004 🢒 Sunfire 🢒 Engine 🢒 Engine Controls - 2.2L (L61) 🢒 Poor Fuel Economy

Inspections

Action

DEFINITION: Fuel economy, as measured by an actual road test, is noticeably lower than expected Also, fuel economy is noticeably lower than the economy was on this vehicle at one time, as previously shown by an actual road test.

Preliminary
    • Refer to Important Preliminary Inspections Before Starting in Symptoms - Engine Controls .
    • Search for bulletins.
    • Inspect the powertrain control module (PCM) grounds for being clean, tight, and in the proper locations. Refer to Power and Grounding Component Views in Wiring Systems and Engine Controls Schematics .
    • Discuss driving habits with the owner.
       - Is the A/C ON or the Defroster mode ON full time?
       - Are the tires at the correct pressure?
       - Are the wheels and tires the correct size?
       - Are there excessively heavy loads being carried?
       - Is the acceleration rate too much, too often?
    • Remove the air filter element and inspect for dirt or for restrictions. Refer to Air Cleaner Element Replacement . Replace as necessary.

Fuel System
    • Discuss with the owner the type, quality, and alcohol content of the fuel. Oxygenated fuels have lower energy and may deliver reduced fuel economy. Refer to Alcohol/Contaminants-in-Fuel Diagnosis .
    • Inspect the fuel injectors. Refer to Fuel Injector Solenoid Coil Test .
    • Test for incorrect fuel pressure. Refer to Fuel System Diagnosis .
    • Inspect for a restricted fuel filter. Refer to Fuel System Diagnosis .
    • Inspect for a contaminated fuel condition. Refer to Alcohol/Contaminants-in-Fuel Diagnosis .
    • Inspect that each fuel injector harness is connected to the correct injector and cylinder. Relocate the injector harnesses as necessary.
    • Inspect for fuel in the pressure regulator vacuum hose. If there is fuel in the hose replace the regulator . Refer to Fuel Pressure Regulator Replacement .

Sensor/System
    • Inspect for the following that may cause the engine to run rich:

Notice: Refer to Heated Oxygen and Oxygen Sensor Notice in the Preface section.

       - Any water intrusion in the HO2S connector
       - The engine oil contaminated by fuel
       - An EVAP canister purge condition--Refer to Scan Tool Data List .
       - Incorrect fuel pressure--Refer to Fuel System Diagnosis .
       - A leaking fuel pressure regulator--Refer to Fuel System Diagnosis .
       - Any leaking fuel injectors--Refer to Fuel System Diagnosis .
       - Any vacuum hoses that are split, kinked, or improperly connected
       - An air intake duct that is collapsed or restricted
       - An air filter that is dirty or restricted--Refer to Air Cleaner Element Replacement .
    • Inspect the air intake system and crankcase for air leaks.
    • Inspect for an engine coolant temperature (ECT) sensor that has shifted in value . Refer to Temperature Versus Resistance .
    • Inspect the crankcase ventilation system for proper operation. Refer to Crankcase Ventilation System Inspection/Diagnosis in Engine Mechanical.
    • Inspect for an inaccurate speedometer. Refer to Symptoms - Instrument Panel, Gages and Console in Instrument Panel, Gages, and Console.
    • Use a scan tool in order to monitor the knock sensor (KS) system for excessive spark retard activity. Refer to Scan Tool Data List .

Ignition System
    • In order to properly inspect the spark plugs or to correct a condition, refer to the following procedures:
       -  Spark Plug Inspection
       -  Spark Plug Replacement
    • Remove spark plugs and inspect for the following conditions:
       - Correct heat range
       - Wet plugs
       - Cracks
       - Wear
       - Improper gap
       - Burned electrodes
       - Heavy deposits
       - Verify that the spark plugs are of the correct type.
    • Inspect for proper ignition voltage output with the J 26792 HEI Spark Tester.
    • An improper spark plug gap will cause a driveability condition. Gap the spark plugs using a wire gage gap tool.
    • Determine the cause of the fouling before replacing the spark plugs.
    • Inspect for damaged or misaligned spark plug boots.
    • Inspect the electronic ignition (EI) module for proper ground connection.
    • Monitor the Misfire Current Counters while driving the vehicle in the conditions that the symptom occurred. If a misfiring cylinder can be located, use the DTC P0300 table for diagnosis. Refer to DTC P0300 .

Engine Cooling System
    • Inspect the engine coolant level for being low. Refer to Loss of Coolant in Engine Cooling.
    • Inspect the engine thermostat for proper operation and for the correct heat range. Refer to Thermostat Diagnosis in Engine Cooling.

Engine Mechanical
    • Inspect engine mechanical for the following conditions:
       - Compression
       - Sticking or leaking valves
       - Worn camshaft lobes
       - Valve timing
       - Worn rocker arms
       - Broken valve springs
       - Excessive oil in combustion chamber or leaking valve seals.
       - For more information, refer to one or more of the following procedures in Engine Mechanical:
    • For incorrect basic engine parts. Inspect the following components:
       - The camshaft--Refer to Camshaft Cleaning and Inspection in Engine Mechanical.
       - The cylinder heads--Refer to Cylinder Head Cleaning and Inspection in Engine Mechanical.
       - The pistons, etc.--Refer to Piston, Connecting Rod, and Bearing Cleaning and Inspection in Engine Mechanical.
    • Refer to Symptoms - Engine Mechanical in Engine Mechanical for diagnosis procedures.

Additional Inspections
    • Visually and physically check the vacuum hoses for splits, kinks, and proper connections and routing as shown on Vehicle Emission Control Information label.
    • Inspect the transmission torque converter clutch (TCC) operation. The scan tool should indicate a RPM drop, when the system commands the TCC ON.
    • Inspect the exhaust system for a possible restriction. Inspect for the following conditions:
       - The exhaust system for damaged or collapsed pipes
       - The mufflers for heat distress or possible internal failure
       - The catalytic converters for being plugged--Refer to Restricted Exhaust in Engine Exhaust.
    • Inspect the brake system for dragging or improper operation. Refer to Symptoms - Hydraulic Brakes in Hydraulic Brakes. Verify that the vehicle operator does not drive with a foot on the brake pedal.